Title 49—Transportation--Volume 1
PART 572—ANTHROPOMORPHIC TEST DEVICES
§ 572.150   Incorporation by reference.
(a) The following materials are incorporated by reference in this subpart R.
(1) A drawings and specifications package entitled “Parts List and Drawings, Subpart R, CRABI 12-Month-Old Infant Crash Test Dummy (CRABI-12, Alpha version) August 2001” and consisting of:
(i) Drawing No. 921022-001, Head Assembly, incorporated by reference in §§ 572.151, 572.152, 572.154, and 572.155;
(ii) Drawing No. 921022-041, Neck Assembly, incorporated by reference in §§ 572.151, 572.153, 572.154, and 572.155;
(iii) Drawing No. TE-3200-160, Headform, incorporated by reference in §§ 572.151 and 572.153;
(iv) Drawing No. 921022-060, Torso Assembly, incorporated by reference in §§ 572.151, 572.154, and 572.155;
(v) Drawing No. 921022-055, Leg Assembly, incorporated by reference in §§ 572.151, and 572.155 as part of a complete dummy assembly;
(vi) Drawing No. 921022-054, Arm Assembly, incorporated by reference in §§ 572.151, and 572.155 as part of the complete dummy assembly;
(2) A procedures manual entitled “Procedures for Assembly, Disassembly and Inspection (PADI) Subpart R, CRABI 12-Month-Old Infant Crash Test Dummy (CRABI-12, Alpha version) August 2001” incorporated by reference in § 572.155;
(3) SAE Recommended Practice J211/1, Rev. Mar95 “Instrumentation for Impact Tests—Part 1—Electronic Instrumentation”, incorporated by reference in § 572.155;
(4) SAE J1733 1994-12 “Sign Convention for Vehicle Crash Testing”, incorporated by reference in § 572.155.
(b) The Director of the Federal Register approved those materials incorporated by reference in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies of the materials may be inspected at NHTSA's Docket Section, 400 Seventh Street S.W., room 5109, Washington, DC, or at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html.
(c) The incorporated materials are available as follows:
(1) The drawings and specifications package referred to in paragraph (a)(1) of this section and the procedures manual referred to in paragraph (a)(2) of this section are available from Reprographic Technologies, 9000 Virginia Manor Road, Beltsville, MD 20705 (301) 419-5070.
(2) The SAE materials referred to paragraphs (a)(3) and (a)(4) of this section are available from the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096.
§ 572.151   General description.
(a) The 12-month-old-infant crash test dummy is described by drawings and specifications containing the following materials:
(1) Technical drawings and specifications package 921022-000 (refer to § 572.150(a)(1)), the titles of which are listed in Table A of this section;
(2) Procedures for Assembly, Disassembly and Inspection document (PADI) (refer to § 572.150(a)(2)).
(b) The dummy consists of the component assemblies set out in the following Table A:
Table A
(c) Adjacent segments of the dummy are joined in a manner such that, except for contacts existing under static conditions, there is no contact between metallic elements throughout the range of motion or under simulated crash impact conditions.
(d) The structural properties of the dummy are such that the dummy shall conform to this Subpart in every respect before its use in any test under this chapter.
§ 572.152   Head assembly and test procedure.
(a) The head assembly (refer to § 572.150(a)(1)(i)) for this test consists of the assembly (drawing 921022-001), triaxial mount block (SA572-80), and 3 accelerometers (drawing SA572-S4).
(b) Frontal and rear impact. (1) Frontal impact. When the head assembly in paragraph (a) of this section is dropped from a height of 376.0 ±1.0 mm (14.8 ±0.04 in) in accordance with paragraph (c)(3)(i) of this section, the peak resultant acceleration measured at the head CG shall not be less than 100 g or more than 120 g. The resultant acceleration vs. time history curve shall be unimodal, and the oscillations occurring after the main pulse shall be less than 17 percent of the peak resultant acceleration. The lateral acceleration shall not exceed ±15 g's.
(2) Rear impact. When the head assembly in paragraph (a) of this section is dropped from a height of 376.0 ±1.0 mm (14.8 ±0.04 in) in accordance with paragraph (c)(3)(ii) of this section, the peak resultant acceleration measured at the head CG shall be not less than 55 g and not more than 71 g. The resultant acceleration vs. time history curve shall be unimodal, and the oscillations occurring after the main pulse shall be less than 17 percent of the peak resultant acceleration. The lateral acceleration shall not exceed ±15 g's.
(c) Head test procedure. The test procedure for the head is as follows:
(1) Soak the head assembly in a controlled environment at any temperature between 18.9 and 25.6 °C (66 and 78 °F) and at any relative humidity between 10 and 70 percent for at least four hours prior to a test. These temperature and humidity levels shall be maintained throughout the entire testing period specified in this section.
(2) Before the test, clean the impact surface of the head skin and the steel impact plate surface with isopropyl alcohol, trichlorethane, or an equivalent. Both impact surfaces shall be clean and dry for testing.
(3)(i) For a frontal impact test, suspend the head assembly with its midsagittal plane in vertical orientation as shown in Figure R1 of this subpart. The lowest point on the forehead is 376.0 ±1.0 mm (14.8 ±0.04 in) from the impact surface. The 3.30 mm (0.13 in) diameter holes located on either side of the dummy's head are used to ensure that the head is level with respect to the impact surface. The angle between the lower surface plane of the neck transducer mass simulator (drawing 910420-003) and the plane of the impact surface is 45 ±1 degrees.
(ii) For a rear impact test, suspend the head assembly with its midsagittal plane in vertical orientation as shown in Figure R2 of this subpart. The lowest point on the back of the head is 376.0 ±1.0 mm (14.8 ±0.04 in) from the impact surface. The 3.30 mm (0.13 in) diameter holes located on either side of the dummy's head are used to ensure that the head is level with respect to the impact surface. The angle between the lower surface plane of the neck transducer structural replacement (drawing 910420-003) and the impact surface is 90 ±1 degrees.
(4) Drop the head assembly from the specified height by a means that ensures a smooth, instant release onto a rigidly supported flat horizontal steel plate which is 50.8 mm (2 in) thick and 610 mm (24 in) square. The impact surface shall be clean, dry and have a micro finish of not less than 203.2 × 10 −6 mm (8 micro inches) (RMS) and not more than 2032.0 × 10 −6 mm (80 micro inches) (RMS).
(5) Allow at least 2 hours between successive tests of the head assembly at the same impact point. For head impacts on the opposite side of the head, the 30-minute waiting period specified in § 572.155(m) does not apply.
§ 572.153   Neck-headform assembly and test procedure.
(a) The neck and headform assembly (refer to §§ 572.150(a)(1)(ii) and 572.150(a)(1)(iii)) for the purposes of this test consists of parts shown in CRABI neck test assembly (drawing TE-3200-100);
(b) When the neck and headform assembly, as defined in § 572.153(a), is tested according to the test procedure in § 572.153(c), it shall have the following characteristics:
(1) Flexion. (i) Plane D referenced in Figure R3 of this subpart shall rotate in the direction of pre-impact flight with respect to the pendulum's longitudinal centerline not less than 75 degrees and not more than 86 degrees. Within this specified rotation corridor, the peak positive moment about the occipital condyles shall be not less than 36 N-m (26.6 ft-lbf) and not more than 45 N-m (33.2 ft-lbf).
(ii) The positive moment about the occipital condyles shall decay for the first time to 5 N-m (3.7 ft-lbf) between 60 ms and 80 ms after time zero.
(iii) The moment about the occipital condyles shall be calculated by the following formula: Moment (N-m) = My − (0.005842m) × (Fx), where My is the moment about the y-axis, Fx is the shear force measured by the neck transducer (drawing SA572 -S23) and 0.005842m is the distance from the point at which the load cell measures the force to the occipital condyle.
(2) Extension. (i) Plane D referenced in Figure R4 of this subpart shall rotate in the direction of preimpact flight with respect to the pendulum's longitudinal centerline not less than 80 degrees and not more than 92 degrees. Within the specified rotation corridor, the peak negative moment about the occipital condyles shall be not more than −12 Nm (−8.9 ft-lbf) and not less than −23 N-m (−17.0 ft-lbf) within the minimum and maximum rotation interval.
(ii) The negative moment about the occipital condyles shall decay for the first time to −5 Nm (−3.7 lbf-ft) between 76 ms and 90 ms after time zero.
(iii) The moment about the occipital condyles shall be calculated by the following formula: Moment (N-m) = My − (0.005842m) × (Fx), where My is the moment about the y-axis, Fx is the shear force measured by the neck transducer (drawing SA572 -S23) and 0.005842m is the distance from the point at which the load cell measures the force to the occipital condyle.
(c) Test procedure. (1) Soak the neck assembly in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and at any relative humidity between 10 and 70 percent for at least four hours prior to a test. These temperature and humidity levels shall be maintained throughout the testing period specified in this section.
(2) Torque the jam nut (drawing 9001336) on the neck cable (drawing ATD-6206) to 0.2 to 0.3 Nm (2-3 in-lbf).
(3) Mount the neck-headform assembly, defined in paragraph (b) of this section, on the pendulum so the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum as shown in Figure R3 for flexion and Figure R4 for extension tests.
(i) The moment and rotation data channels are defined to be zero when the longitudinal centerline of the neck and pendulum are parallel.
(ii) The test shall be conducted without inducing any torsion of the neck.
(4) Release the pendulum and allow it to fall freely to achieve an impact velocity of 5.2 ±0.1 m/s (17.1 ±0.3 ft/s) for flexion and 2.5 ±0.1 m/s (8.2 ±0.3 ft/s) for extension measured at the center of the pendulum accelerometer at the instant of contact with the honeycomb.
(i) Time-zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material. The pendulum data channel shall be defined to be zero at this time.
(ii) Stop the pendulum from the initial velocity with an acceleration vs. time pulse which meets the velocity change as specified in the following table. Integrate the pendulum acceleration data channel to obtain the velocity vs. time curve as indicated in Table B:
Table B—Pendulum Pulse
§ 572.154   Thorax assembly and test procedure.
(a) Thorax Assembly (refer to § 572.150(a)(1)(iv)) . The thorax consists of the part of the torso assembly shown in drawing 921022-060.
(b) When the thorax of a completely assembled dummy (drawing 921022-000) is impacted by a test probe conforming to § 572.155(a) at 5.0 ±0.1m/s (16.5 ±0.3 ft/s) according to the test procedure in paragraph (c) of this section, the peak force, measured by the impact probe in accordance with paragraph § 572.155(a), shall be not less than 1514 N (340.7 lbf) and not more than 1796 N (404.1 lbf).
(c) Test procedure. (1) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and at any relative humidity between 10 and 70 percent for at least four hours prior to a test. These temperature and humidity levels shall be maintained throughout the entire testing period specified in this section.
(2) The test dummy is clothed in a cotton-polyester based tight fitting sweat shirt with long sleeves and ankle long pants whose combined weight is not more than 0.25 kg (.55 lbs).
(3) Seat and orient the dummy on a level seating surface without back support as shown in Figure R5 of this subpart, with the lower limbs extended forward, parallel to the midsagittal plane and the arms 0 to 5 degrees forward of vertical. The dummy's midsagittal plane is vertical within ±/1 degree and the posterior surface of the upper spine box is aligned at 90 ±/1 degrees from the horizontal. (Shim material may be used under the upper legs to maintain the dummy's specified spine box surface alignment).
(4) Establish the impact point at the chest midsagittal plane so that the impact point of the longitudinal centerline of the probe coincides with the dummy's midsagittal plane, is centered on the torso 196 ±/2.5 mm (7.7 ±/0.1 in) vertically from the plane of the seating surface, and is within 0.5 degrees of a horizontal plane.
(5) Impact the thorax with the test probe so that at the moment of contact the probe's longitudinal center line falls within 2 degrees of a horizontal line in the dummy's midsagittal plane.
(6) Guide the test probe during impact so that there is no significant lateral, vertical or rotational movement.
(7) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.155   Test conditions and instrumentation.
(a) The test probe for thoracic impacts, except for attachments, shall be of rigid metallic construction and concentric about its longitudinal axis. Any attachments to the impactor, such as suspension hardware, impact vanes, etc., must meet the requirements of § 572.154(c)(7). The impactor shall have a mass of 2.86 ±0.02 kg (6.3 ±0.05 lbs) and a minimum mass moment of inertia of 164 kg-cm 2 (0.145 lb-in-sec 2 ) in yaw and pitch about the CG of the probe. One-third of the weight of suspension cables and any attachments to the impact probe must be included in the calculation of mass, and such components may not exceed five percent of the total weight of the test probe. The impacting end of the probe, perpendicular to and concentric with the longitudinal axis of the probe, has a flat, continuous, and non-deformable 101.6 ±0.25 mm (4.00 ±0.01 in) diameter face with an edge radius of 7.6/12.7 mm (0.3/0.5 in). The impactor shall have a 101-103 mm (4-4.1 in) diameter cylindrical surface extending for a minimum of 12.5 mm (0.5 in) to the rear from the impact face. The probe's end opposite to the impact face has provisions for mounting an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe. The impact probe shall have a free air resonant frequency of not less than 1000 Hz measured in line with the longitudinal axis of the impactor, using the test method shown in the Procedures for Assembly, Disassembly and Inspection (PADI) document referenced in § 572.151.
(b) Head accelerometers shall have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 and be mounted in the head as shown in drawing 921022-000.
(c) The neck force-moment transducer shall have the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S23 and shall be mounted for testing as shown in drawing 921022-000 and in figures R3 and R4 of this subpart.
(d) The shoulder force transducers shall have the dimensions and response characteristics specified in drawing SA572-S25 and are allowed to be mounted as optional instrumentation in place of part No. 921022-022 in the torso assembly as shown in drawing 921022-000.
(e) The thorax accelerometers shall have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 and be mounted in the torso assembly in triaxial configuration as shown in drawing 921022-000.
(f) The lumbar spine and lower neck force/moment transducer shall have the dimensions and response characteristics specified in drawing SA572-S23 and are allowed to be mounted as optional instrumentation in the torso assembly in place of part No. 910420-003 as shown in drawing 921022-000.
(g) The pelvis accelerometers shall have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 and are allowed to be mounted as optional instrumentation in the pelvis in triaxial configuration as shown in drawing 921022-000.
(h) The pubic force transducer shall have the dimensions and response characteristics specified in drawing SA572-S24 and is allowed to be mounted as optional instrumentation in place of part No. 921022-050 in the torso assembly as shown in drawing 921022-000.
(i) The outputs of acceleration and force-sensing devices installed in the dummy and in the test apparatus specified by this part are recorded in individual data channels that conform to the requirements of SAE Recommended Practice J211/1, Rev. Mar95 “Instrumentation for Impact Tests—Part 1—Electronic Instrumentation” (refer to § 572.150(a)(3)), with channel classes as follows:
(1) Head and headform acceleration—Class 1000.
(2) Neck :
(i) Forces—Class 1000;
(ii) Moments—Class 600;
(iii) Pendulum acceleration—Class 180;
(iv) Rotation potentiometer response (if used)—CFC 60.
(3) Thorax:
(i) Spine and pendulum accelerations—Class 180;
(ii) Shoulder forces—Class 600;
(4) Lumbar:
(i) Forces—Class 1000;
(ii) Moments—Class 600;
(5) Pelvis:
(i) Accelerations—Class 1000;
(ii) Pubic—Class 1000.
(j) Coordinate signs for instrumentation polarity shall conform to SAE J1733, 1994-12, “Sign Convention For Vehicle Crash Testing, Surface Vehicle Information Report,” (refer to § 572.150(a)(4)).
(k) The mountings for sensing devices shall have no resonance frequency within a range of 3 times the frequency range of the applicable channel class.
(l) Limb joints shall be set at l g, barely restraining the weight of the limb when it is extended horizontally. The force required to move a limb segment shall not exceed 2 g throughout the range of limb motion.
(m) Performance tests of the same component, segment, assembly, or fully assembled dummy shall be separated in time by period of not less than 30 minutes unless otherwise noted.
(n) Surfaces of dummy components may not be painted except as specified in this subpart or in drawings referenced in § 572.150.
§ 572.160   Incorporation by reference.
(a) The following materials are hereby incorporated into this subpart S by reference:
(1) A drawings and specifications package entitled, “Parts List and Drawings, Part 572 Subpart S, Hybrid III 6-Year-Old Child Weighted Crash Test Dummy (H-III6CW),” dated June 2009, incorporated by reference in § 572.161 and consisting of:
(i) Drawing No. 167-0000, Complete Assembly, incorporated by reference in § 572.161;
(ii) Drawing No. 167-2000, Upper Torso Assembly, incorporated by reference in §§ 572.161, 572.164, and 572.165 as part of a complete dummy assembly;
(iii) Drawing No. 167-2020, Revision A, Spine Box Weight, incorporated by reference in §§ 572.161, 572.164, and 572.165 as part of a complete dummy assembly;
(iv) Drawing No. 167-3000, Lower Torso Assembly, incorporated by reference in §§ 572.161, and 572.165 as part of a complete dummy assembly;
(v) Drawing No. 167-3010, Revision A, Lumbar Weight Base, incorporated by reference in §§ 572.161 and 572.165 as part of a complete dummy assembly; and
(vi) The Hybrid III Weighted Six-Year-Old Child Parts/Drawing List, incorporated by reference in § 572.161.
(2) A procedures manual entitled, “Procedures for Assembly, Disassembly, And Inspection (PADI) of the Part 572 Subpart S, Hybrid III 6-Year-Old Child Weighted Crash Test Dummy (H-III6CW), revised June 2009,” incorporated by reference in § 572.161;
(3) The Director of the Federal Register approved the materials incorporated by reference in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies of the materials may be inspected at the Department of Transportation, Docket Operations, Room W12-140, 1200 New Jersey Avenue, SE., Washington, DC 20590, telephone (202) 366-9826, and at the National Archives and Records Administration (NARA), and in electronic format through Regulations.gov. For information on the availability and inspection of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. For information on the availability and inspection of this material at Regulations.gov, call 1-877-378-5457, or go to: http://www.regulations.gov.
(b) The incorporated materials are available as follows:
(1) The Drawings and Specifications for the Hybrid III Six-Year-Old Weighted Child Test Dummy referred to in paragraph (a)(1) of this section are available in electronic format through the NHTSA docket center and in paper format from Leet-Melbrook, Division of New RT, 18810 Woodfield Road, Gaithersburg, MD 20879, (301) 670-0090.
(2) [Reserved]
§ 572.161   General description.
(a) The Hybrid III Six-Year-Old Weighted Child Test Dummy is defined by drawings and specifications containing the following materials:
(1) “Parts List and Drawings, Part 572 Subpart S, Hybrid III 6-Year-Old Child Weighted Crash Test Dummy (H-III6CW),” dated June 2009 (incorporated by reference, see § 572.160);
(2) The head, neck, arm, and leg assemblies specified in 49 CFR 572 subpart N; and
(3) “Procedures for Assembly, Disassembly, And Inspection (PADI) of the Part 572 Subpart S, Hybrid III 6-Year-Old Child Weighted Crash Test Dummy (H-III6CW), revised June 2009” (incorporated by reference, see § 572.160).
Table A
1 Head, neck, arm, and leg assemblies are as specified in 49 CFR 572 subpart N.
(b) Adjacent segments are joined in a manner such that except for contacts existing under static conditions, there is no contact between metallic elements throughout the range of motion or under simulated crash impact conditions.
(c) The structural properties of the dummy are such that the dummy must conform to Subpart S in every respect and Subpart N as applicable, before use in any test similar to those specified in Standard 208, “Occupant Crash Protection” (49 CFR 571.208), and Standard 213, “Child Restraint Systems” (49 CFR 571.213).
§ 572.162   Head assembly and test procedure.
The head assembly is assembled and tested as specified in 49 CFR 572.122 (Subpart N).
§ 572.163   Neck assembly and test procedure.
The neck assembly is assembled and tested as specified in 49 CFR 572.123 (Subpart N).
§ 572.164   Thorax assembly and test procedure.
(a) Thorax (upper torso) assembly. The thorax consists of the part of the torso assembly shown in drawing 167-2000 (incorporated by reference, see § 572.160).
(b) When the anterior surface of the thorax of a completely assembled dummy (drawing 167-2000) that is seated as shown in Figure S1 is impacted by a test probe conforming to 49 CFR 572.127(a) at 6.71 ±0.12 m/s (22.0 ±0.4 ft/s) according to the test procedure specified in 49 CFR 572.124(c):
(1) The maximum sternum displacement relative to the spine, measured with chest deflection transducer (specified in 49 CFR 572.124(b)(1)), must be not less than 38.0 mm (1.50 in) and not more than 46.0 mm (1.80 in). Within this specified compression corridor, the peak force, measured by the probe in accordance with 49 CFR 572.127, must be not less than 1205 N (270.9 lbf) and not more than 1435 N (322.6 lbf). The peak force after 12.5 mm (0.5 in) of sternum displacement, but before reaching the minimum required 38.0 mm (1.46 in) sternum displacement limit, must not exceed an upper limit of 1500 N.
(2) The internal hysteresis of the ribcage in each impact as determined by the plot of force vs. deflection in paragraph (b)(1) of this section must be not less than 65 percent but not more than 85 percent.
(c) Test procedure. The thorax assembly is tested as specified in 49 CFR 572.124(c).
§ 572.165   Upper and lower torso assemblies and torso flexion test procedure.
(a) Upper/lower torso assembly. The test objective is to determine the stiffness effects of the lumbar spine (specified in 49 CFR 572.125(a)), including cable (specified in 49 CFR 572.125(a)), mounting plate insert (specified in 49 CFR 572.125(a)), nylon shoulder bushing (specified in 49 CFR 572.125(a)), nut (specified in 49 CFR 572.125(a)), spine box weighting plates (drawing 167-2020 Revision A), lumbar base weight (drawing 167-3010 Revision A), and abdominal insert (specified in 49 CFR 572.125(a)), on resistance to articulation between the upper torso assembly (drawing 167-2000) and the lower torso assembly (drawing 167-3000). Drawing Nos. 167-2000, 167-2020 Revision A, 167-3000, and 167-3010 Revision A, are incorporated by reference, see § 572.160.
(b)(1) When the upper torso assembly of a seated dummy is subjected to a force continuously applied at the head to neck pivot pin level through a rigidly attached adaptor bracket as shown in Figure S2 according to the test procedure set out in 49 CFR 572.125(c), the lumbar spine-abdomen assembly must flex by an amount that permits the upper torso assembly to translate in angular motion until the machined surface of the instrument cavity at the back of the thoracic spine box is at 45 ±0.5 degrees relative to the transverse plane, at which time the force applied as shown in Figure S2 must be within 88.6 N ±25 N (20.0 lbf ±5.6 lbf), and
(2) Upon removal of the force, the torso assembly must return to within 9 degrees of its initial position.
(c) Test procedure. The upper and lower torso assemblies are tested as specified in 49 CFR 572.125(c), except that in paragraph (c)(5) of that section, the initial torso orientation angle may not exceed 32 degrees.
§ 572.166   Knees and knee impact test procedure.
The knee assembly is assembled and tested as specified in 49 CFR 572.126 (Subpart N).
§ 572.167   Test conditions and instrumentation.
The test conditions and instrumentation are as specified in 49 CFR 572.127 (Subpart N).
§ 572.170   Incorporation by reference.
(a) Certain material is incorporated by reference (IBR) into this part with the approval of the Director of the Federal Register under 5 U.S.C. 552(a) and 1 CFR part 51. To enforce any edition other than that specified in this section, NHTSA must publish notice of change in the Federal Register and the material must be available to the public. All approved material is available for inspection at the Department of Transportation, Docket Operations, Room W12-140, telephone 202-366-9826, and is available from the sources listed below. The material is available in electronic format through Regulations.gov, call 1-877-378-5457 or go to www.regulations.gov. It is also available for inspection at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, call 202-741-6030 or go to http://www.archives.gov/federal-register/cfr/ibr-locations.html.
(b) NHTSA Technical Information Services, 1200 New Jersey Ave., SE., Washington, DC 20590, telephone 202-366-5965.
(1) A parts/drawing list entitled, “Parts/Drawing List, Part 572 Subpart T, Hybrid III 10 Year Old Child Test Dummy (HIII-10C), March, 2015,” IBR approved for § 572.171.
(2) A drawings and inspection package entitled, “Parts List and Drawings, Part 572 Subpart T, Hybrid III 10 Year Old Child Crash Dummy (HIII-10C), March 2015,” IBR approved for § 572.171, including:
(i) Drawing No. 420-0000, Complete Assembly HIII 10-year-old, IBR approved for §§ 572.171, 572.172, 572.173, 572.174, 572.176, and 572.177.
(ii) Drawing No. 420-1000, Head Assembly, IBR approved for § 572.171, § 572.172, § 572.173, and § 572.177.
(iii) Drawing No. 420-2000, Neck Assembly, IBR approved for §§ 572.171, 572.173, and 572.177.
(iv) Drawing No. 420-3000, Upper Torso Assembly, IBR approved for §§ 572.171, 572.174, 572.175, and 572.177.
(v) Drawing No. 420-4000, Lower Torso Assembly, IBR approved for §§ 572.171, 572.174, 572.175, and 572.177.
(vi) Drawing No. 420-5000-1, Complete Leg Assembly—left, IBR approved for §§ 572.171, 572.176, and 572.177.
(vii) Drawing No. 420-5000-2, Complete Leg Assembly—right, IBR approved for §§ 572.171, 572.176, and 572.177.
(viii) Drawing No. 420-7000-1, Complete Arm Assembly—left, IBR approved for § 572.171, and,
(ix) Drawing No. 420-7000-2, Complete Arm Assembly—right, IBR approved for § 572.171.
(3) A procedures manual entitled “Procedures for Assembly, Disassembly, and Inspection (PADI) of the Hybrid III 10 Year Old Child Test Dummy (HIII-10C), March 2015”; IBR approved for §§ 572.171 and 572.177.
(c) SAE International, 400 Commonwealth Drive, Warrendale, PA 15096, call 1-877-606-7323.
(1) SAE Recommended Practice J211/1, Rev. Mar 95, “Instrumentation for Impact Tests—Part 1—Electronic Instrumentation,” IBR approved for § 572.177.
(2) SAE Information Report J1733 of 1994-12, “Sign Convention for Vehicle Crash Testing,” December 1994, IBR approved for § 572.177.
§ 572.171   General description.
(a) The Hybrid III 10-year-old Child Test Dummy (HIII-10C) is defined by drawings and specifications containing the following materials:
(1) The parts enlisted in “Parts/Drawing List, Part 572 Subpart T, Hybrid III 10 Year Old Child Test Dummy (HIII-10C), March, 2015” (incorporated by reference, see § 572.170),
(2) The engineering drawings and specifications contained in “Parts List and Drawings, Part 572 Subpart T, Hybrid III 10 Year Old Child Crash Dummy (HIII-10C), March 2015,” which includes the engineering drawings and specifications described in Drawing 420-0000, the titles of the assemblies of which are listed in Table A, and,
(3) A manual entitled “Procedures for Assembly, Disassembly, and Inspection (PADI) of the Hybrid III 10 Year Old Child Test Dummy (HIII-10C), March 2015.”
Table A
(b) The structural properties of the dummy are such that the dummy conforms to this Subpart in every respect before use in any test.
§ 572.172   Head assembly and test procedure.
(a) The head assembly for this test consists of the complete head (drawing 420-1000), a six-axis neck transducer (drawing SA572-S11, included in drawing 420-0000), or its structural replacement (drawing 420-383X), and 3 accelerometers (drawing SA572-S4, included in drawing 420-0000) (all incorporated by reference, see § 572.170).
(b) When the head assembly is dropped from a height of 376.0 ±1.0 mm (14.8 ±0.04 in) in accordance with paragraph (c) of this section, the peak resultant acceleration at the location of the accelerometers at the head CG may not be less than 250 G or more than 300 G. The resultant acceleration vs. time history curve shall be unimodal; oscillations occurring after the main pulse must be less than 10 percent of the peak resultant acceleration. The lateral acceleration shall not exceed 15 G (zero to peak).
(c) Head test procedure. The test procedure for the head is as follows:
(1) Soak the head assembly in a controlled environment at any temperature between 18.9 and 25.6 °C (66 and 78 °F) and a relative humidity from 10 to 70 percent for at least four hours prior to a test.
(2) Prior to the test, clean the impact surface of the skin and the impact plate surface with isopropyl alcohol, trichloroethane, or an equivalent. The skin of the head must be clean and dry for testing.
(3) Suspend and orient the head assembly as shown in Figure T1. The lowest point on the forehead must be 376.0 ±1.0 mm (14.8 ±0.04 in) from the impact surface. The 1.57 mm (0.062 in) diameter holes located on either side of the dummy's head shall be used to ensure that the head is level with respect to the impact surface.
(4) Drop the head assembly from the specified height by means that ensure a smooth, instant release onto a rigidly supported flat horizontal steel plate which is 50.8 mm (2 in) thick and 610 mm (24 in) square. The impact surface shall be clean, dry and have a micro finish of not less than 203.2 × 10 −6 mm (8 micro inches) (RMS) and not more than 2032.0 × 10 −6 mm (80 micro inches) (RMS).
(5) Allow at least 2 hours between successive tests on the same head.
§ 572.173   Neck assembly and test procedure.
(a) The neck assembly for the purposes of this test consists of the assembly of components shown in drawing 420-2000 (incorporated by reference, see § 572.170).
(b) When the head-neck assembly consisting of the head (drawing 420-1000), neck (drawing 420-2000), six-channel neck transducer (SA572-S11, included in drawing 420-0000), lower neck bracket assembly (drawing 420-2070), and either three uniaxial accelerometers (drawing SA572-S4, included in drawing 420-0000) or their mass equivalent installed in the head assembly as specified in drawing 420-1000 (all incorporated by reference, see § 572.170), is tested according to the test procedure in paragraph (c) of this section, it shall have the following characteristics:
(1) Flexion. (i) Plane D, referenced in Figure T2, shall rotate in the direction of preimpact flight with respect to the pendulum's longitudinal centerline between 76 degrees and 90 degrees. During the time interval while the rotation is within the specified corridor, the peak moment, measured by the neck transducer (drawing SA572-S11, included in drawing 420-0000) (incorporated by reference, see § 572.170), about the occipital condyles may not be less than 50 N-m (36.9 ft-lbf) and not more than 62 N-m (45.7 ft-lbf). The positive moment shall decay for the first time to 10 N-m (7.4 ft-lbf) between 86 ms and 105 ms after time zero.
(ii) The moment shall be calculated by the following formula: Moment (N-m) = M y − (0.01778) × (F X ).
(iii) M y is the moment about the y-axis in Newton-meters, F X is the shear force measured by the neck transducer (drawing SA572-S11) in Newtons, and 0.01778 is the distance in meters from the load center of the neck transducer to the occipital condyle.
(2) Extension. (i) Plane D, referenced in Figure T3, shall rotate in the direction of preimpact flight with respect to the pendulum's longitudinal centerline between 96 degrees and 115 degrees. During the time interval while the rotation is within the specified corridor, the peak moment, measured by the neck transducer (drawing SA572-S11, included in drawing 420-0000) (incorporated by reference, see § 572.170), about the occipital condyles may not be more than −37 N-m (−27.3 ft-lbf) and not less than −46 N-m (−33.9 ft-lbf). The positive moment shall decay for the first time to −10 N-m (−7.4 ft-lbf) between 100 ms and 116 ms after time zero.
(ii) The moment shall be calculated by the following formula: Moment (N-m) = M y − (0.01778) × (F X ).
(iii) M y is the moment about the y-axis in Newton-meters, F X is the shear force measured by the neck transducer (drawing SA572-S11, included in drawing 420-0000) (incorporated by reference, see § 572.170) in Newtons, and 0.01778 is the distance in meters from the load center of the neck transducer to the occipital condyle.
(3) Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material. All data channels shall be at the zero level at this time.
(c) Test procedure. The test procedure for the neck assembly is as follows:
(1) Soak the neck assembly in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and a relative humidity between 10 and 70 percent for at least four hours prior to a test.
(2) Torque the hex nut (drawing 420-2000, part 9000130) on the neck cable (drawing 420-2060) (both incorporated by reference, see § 572.170) to 0.9 ±0.2 N-m (8 ±2 in-lbf) before each test on the same neck.
(3) Mount the head-neck assembly, defined in paragraph (b) of this section, on the pendulum described in Figure 22 of 49 CFR part 572 so that the leading edge of the lower neck bracket coincides with the leading edge of the pendulum as shown in Figure T2 for flexion tests and Figure T3 for extension tests.
(4)(i) Release the pendulum and allow it to fall freely from a height to achieve an impact velocity of 6.1 ±0.12 m/s (20.0 ±0.4 ft/s) for flexion tests and 5.03 ±0.12 m/s (16.50 ±0.40 ft/s) for extension tests, measured by an accelerometer mounted on the pendulum as shown in Figure T2 at the instant of contact with the honeycomb.
(ii) Stop the pendulum from the initial velocity with an acceleration vs. time pulse that meets the velocity change as specified below. Integrate the pendulum acceleration data channel to obtain the velocity vs. time curve:
Table B—Pendulum Pulse
§ 572.174   Thorax assembly and test procedure.
(a) The thorax consists of the part of the torso assembly designated as the upper torso (drawing 420-3000) (incorporated by reference, see § 572.170).
(b) When the anterior surface of the thorax of a completely assembled dummy (drawing 420-0000) (incorporated by reference, see § 572.170) is impacted by a test probe conforming to section 572.177 at 6.00 ±0.12 m/s (22.0 ±0.4 ft/s) according to the test procedure in paragraph (c) of this section:
(1) Maximum sternum displacement (compression) relative to the spine, measured with chest deflection transducer (drawing SA572-T4, included in drawing 420-0000) (incorporated by reference, see § 572.170), must be not less than 37 mm (1.46 in) and not more than 46 mm (1.81 in). Within this specified compression corridor, the peak force, measured by the impact probe as defined in section 572.177 and calculated in accordance with paragraph (b)(3) of this section, shall not be less than 2.0 kN (450 lbf) and not more than 2.45 kN (551 lbf). The peak force after 20 mm (0.79 in.) of sternum displacement but before reaching the minimum required 37 mm (1.46 in.) sternum displacement limit shall not exceed 2.52 kN (567 lbf).
(2) The internal hysteresis of the ribcage in each impact as determined by the plot of force vs. deflection in paragraph (a)(1) of this section shall be not less than 69 percent but not more than 85 percent. The hysteresis shall be calculated by determining the ratio of the area between the loading (from time zero to maximum deflection) and unloading portions (from maximum deflection to zero force) of the force deflection curve to the area under the loading portion of the curve.
(3) The force shall be calculated by the product of the impactor mass and its measured deceleration.
(c) Test Procedure. The test procedure for the thorax assembly is as follows:
(1) The dummy is clothed in a form fitting cotton stretch above-the-elbow sleeved shirt and above-the-knees pants. The weight of the shirt and pants shall not exceed 0.14 kg (0.30 lb) each.
(2) Torque the lumbar cable (drawing 420-4130) (incorporated by reference, see § 572.170) to 0.9 ±0.2 N-m (8 ±2 in-lbf) and set the lumbar adjustment angle to 12 degrees. Set the neck angle to 16 degrees.
(3) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and a relative humidity between 10 and 70 percent for at least four hours prior to a test.
(4) Seat and orient the dummy on a seating surface without back support as shown in Figure T4, with the limbs extended horizontally and forward, parallel to the midsagittal plane, the midsagittal plane vertical within ±1 degree and the ribs level in the anterior-posterior and lateral directions within ±0.5 degrees.
(5) Establish the impact point at the chest midsagittal plane so that the impact point of the longitudinal centerline of the probe coincides with the midsagittal plane of the dummy within ±2.5 mm (0.1 in) and is 12.7 ±1.1 mm (0.5 ±0.04 in) below the horizontal-peripheral centerline of the No. 3 rib and is within 0.5 degrees of a horizontal line in the dummy's midsagittal plane.
(6) Impact the thorax with the test probe so that at the moment of contact the probe's longitudinal centerline falls within 2 degrees of a horizontal line in the dummy's midsagittal plane.
(7) Guide the test probe during impact so that there is no significant lateral, vertical, or rotational movement.
(8) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.175   Upper and lower torso assemblies and torso flexion test procedure.
(a) The test objective is to determine the stiffness of the molded lumbar assembly (drawing 420-4100), abdominal insert (drawing 420-4300), and chest flesh assembly (drawing 420-3560) on resistance to articulation between the upper torso assembly (drawing 420-3000) and lower torso assembly (drawing 420-4000) (all incorporated by reference, see § 572.170).
(b) When the upper torso assembly of a seated dummy is subjected to a force continuously applied at the head to neck pivot pin level through a rigidly attached adaptor bracket as shown in Figure T5 according to the test procedure set out in paragraph (c) of this section:
(1) The lumbar spine-abdomen-chest flesh assembly shall flex by an amount that permits the upper torso assembly to translate in angular motion relative to the vertical transverse plane 35 ±0.5 degrees at which time the force applied must be not less than 180 N (40.5 lbf) and not more than 250 N (56.2 lbf).
(2) Upon removal of the force, the torso assembly must return to within 8 degrees of its initial position.
(c) Test Procedure. The test procedure for the upper/lower torso assembly is as follows:
(1) Torque the lumbar cable (drawing 420-4130) (incorporated by reference, see § 572.170) to 0.9 ±0.2 N-m (8 ±2 in-lbf) and set the lumbar adjustment angle to 12 degrees. Set the neck angle to 16 degrees.
(2) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and a relative humidity between 10 and 70 percent for at least four hours prior to a test.
(3) Assemble the complete dummy (with or without the legs below the femurs) and attach to the fixture in a seated posture as shown in Figure T5.
(4) Secure the pelvis to the fixture at the pelvis instrument cavity rear face by threading four 1/4 -inch cap screws into the available threaded attachment holes. Tighten the mountings so that the test material is rigidly affixed to the test fixture and the pelvic-lumbar joining surface is 18 degrees from horizontal and the legs are parallel with the test fixture.
(5) Attach the loading adaptor bracket to the spine of the dummy as shown in Figure T5.
(6) Inspect and adjust, if necessary, the seating of the abdominal insert within the pelvis cavity and with respect to the chest flesh, assuring that the chest flesh provides uniform fit and overlap with respect to the outside surface of the pelvis flesh.
(7) Flex the dummy's upper torso three times between the vertical and until the torso reference frame, as shown in Figure T5, reaches 30 degrees from the vertical transverse plane. Bring the torso to vertical orientation and wait for 30 minutes before conducting the test. During the 30-minute waiting period, the dummy's upper torso shall be externally supported at or near its vertical orientation to prevent it from drooping.
(8) Remove all external support and wait two minutes. Measure the initial orientation angle of the torso reference plane of the seated, unsupported dummy as shown in Figure T5. The initial orientation angle may not exceed 20 degrees.
(9) Attach the pull cable and the load cell as shown in Figure T5.
(10) Apply a tension force in the midsagittal plane to the pull cable as shown in Figure T5 at any upper torso deflection rate between 0.5 and 1.5 degrees per second, until the angle reference plane is at 35 ±0.5 degrees of flexion relative to the vertical transverse plane.
(11) Continue to apply a force sufficient to maintain 35 ±0.5 degrees of flexion for 10 seconds, and record the highest applied force during the 10-second period.
(12) Release all force at the attachment bracket as rapidly as possible, and measure the return angle with respect to the initial angle reference plane as defined in paragraph (c)(7) of this section three minutes after the release.
§ 572.176   Knees and knee impact test procedure.
(a) The knee assembly for the purpose of this test is the part of the leg assembly shown in drawing 420-5000 (incorporated by reference, see § 572.170).
(b) When the knee assembly, consisting of lower upper leg assembly (420-5200), femur load transducer (SA572-S10, included in drawing 420-0000) or its structural replacement (420-5121), lower leg assembly (420-5300), ankle assembly (420-5400), and foot molded assembly (420-5500) (all incorporated by reference, see § 572.170) is tested according to the test procedure in subsection (c) of this section:
(1) The peak resistance force as measured with the test probe-mounted accelerometer must not be less than 2.6 kN (585 lbf) and not more than 3.2 kN (719 lbf).
(2) The force shall be calculated by the product of the impactor mass and its deceleration.
(c) Test Procedure. The test procedure for the knee assembly is as follows:
(1) Soak the knee assembly in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and a relative humidity between 10 and 70 percent for at least four hours prior to a test.
(2) Mount the test material and secure it to a rigid test fixture as shown in Figure T6. No part of the foot or tibia may contact any exterior surface.
(3) Align the test probe so that throughout its stroke and at contact with the knee it is within 2 degrees of horizontal and collinear with the longitudinal centerline of the femur.
(4) Guide the pendulum so that there is no significant lateral, vertical, or rotational movement at the time of initial contact between the impactor and the knee.
(5) The test probe velocity at the time of contact shall be 2.1 ±0.03 m/s (6.9 ±0.1 ft/s).
(6) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.177   Test conditions and instrumentation.
(a) The following test equipment and instrumentation is needed for qualification as set forth in this subpart:
(1) The test probe for thoracic impacts is of rigid metallic construction, concentric in shape, and symmetric about its longitudinal axis. It has a mass of 6.89 ±0.05 kg (15.2 ±0.1 lb) and a minimum mass moment of inertia of 2040 kg-cm 2 (1.81 lbf-in-sec 2 ) in yaw and pitch about the CG. One-third ( 1/3 ) of the weight of the suspension cables and their attachments to the impact probe is included in the calculation of mass, and such components may not exceed five percent of the total weight of the test probe. The impacting end of the probe, perpendicular to and concentric with the longitudinal axis, is at least 25.4 mm (1.0 in) long, and has a flat, continuous, and non-deformable 121 ±0.25 mm (4.76 ±0.01 in) diameter face with a maximum edge radius of 12.7 mm (0.5 in). The probe's end opposite to the impact face has provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe. No concentric portions of the impact probe may exceed the diameter of the impact face. The impact probe has a free air resonant frequency of not less than 1000 Hz, which may be determined using the procedure listed in the PADI (incorporated by reference, see § 572.170).
(2) The test probe for knee impacts is of rigid metallic construction, concentric in shape, and symmetric about its longitudinal axis. It has a mass of 1.91 ±0.05 kg (4.21 ±0.1 lb) and a minimum mass moment of inertia of 140 kg-cm 2 (0.124 lbf-in-sec 2 ) in yaw and pitch about the CG. One third ( 1/3 ) of the weight of the suspension cables and their attachments to the impact probe may be included in the calculation of mass, and such components may not exceed five percent of the total weight of the test probe. The impacting end of the probe, perpendicular to and concentric with the longitudinal axis, is at least 12.5 mm (0.5 in) long, and has a flat, continuous, and non-deformable 76.2 ±0.2 mm (3.00 ±0.01 in) diameter face with a maximum edge radius of 12.7 mm (0.5 in). The probe's end opposite to the impact face has provisions for mounting an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe. No concentric portions of the impact probe may exceed the diameter of the impact face. The impact probe has a free air resonant frequency of not less than 1000 Hz, which may be determined using the procedure listed in the PADI (incorporated by reference, see § 572.170).
(3) Head accelerometers have dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 (included in drawing 420-0000) and are mounted in the head as shown in drawing 420-0000 (both incorporated by reference, see § 572.170), sheet 2 of 6.
(4) The upper neck force and moment transducer has the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S11 (included in drawing 420-0000) and is mounted in the head-neck assembly as shown in drawing 420-0000 (both incorporated by reference, see § 572.170), sheet 2 of 6.
(5) The chest deflection transducer has the dimensions and response characteristics specified in drawing SA572-S50 (included in drawing 420-0000) and is mounted to the upper torso assembly as shown in drawing 420-0000 (both incorporated by reference, see § 572.170), sheet 2 of 6.
(b) The following instrumentation may be required for installation in the dummy for compliance testing. If so, it is installed during qualification procedures as described in this subpart:
(1) The thorax CG accelerometers have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 (included in drawing 420-0000) (incorporated by reference, see § 572.170) and are mounted in the torso assembly in a triaxial configuration within the spine box instrumentation cavity.
(2) The lower neck force and moment transducer has the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S40 (included in drawing 420-0000) and is mounted to the neck assembly by replacing the lower neck mounting bracket 420-2070 as shown in drawing 420-2000 (all incorporated by reference, see § 572.170).
(3) The clavicle force transducers have the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S41 (included in drawing 420-0000) and are mounted in the shoulder assembly as shown in drawing 420-3800 (both incorporated by reference, see § 572.170).
(4) The IR-Tracc chest deflection transducers have the dimensions and response characteristics specified in drawing SA572-S43 (included in drawing 420-0000) and are mounted to the spine box assembly as shown in drawing 420-8000 (both incorporated by reference, see § 572.170).
(5) The spine and sternum accelerometers have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 (included in drawing 420-0000) and are mounted in the torso assembly in uniaxial fore-and-aft oriented configuration arranged as corresponding pairs in two locations each on the sternum and at the spine box of the upper torso assembly as shown in drawing 420-0000 (both incorporated by reference, see § 572.170), sheet 2 of 6.
(6) The lumbar spine force-moment transducer has the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S12 (included in drawing 420-0000) and is mounted in the lower torso assembly as shown in drawing 420-4000 (both incorporated by reference, see § 572.170).
(7) The iliac force transducers have the dimensions and response characteristics specified in drawing SA572-S13 L and R (included in drawing 420-0000) and are mounted in the lower torso assembly as shown in drawing 420-4000 (both incorporated by reference, see § 572.170).
(8) The pelvis accelerometers have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 (included in drawing 420-0000) and are mounted in the torso assembly in triaxial configuration in the pelvis bone as shown in drawing 420-0000 (both incorporated by reference, see § 572.170), sheet 2 of 6.
(9) The femur force and moment transducers (SA572-S10, included in drawing 420-0000) have the dimensions, response characteristics, and sensitive axis locations specified in the appropriate drawing and are mounted in the upper leg assembly, replacing the femur load cell simulator (drawing 420-5121) as shown in drawing 420-5100 (all incorporated by reference, see § 572.170).
(10) The tilt sensors have the dimensions and response characteristics specified in drawing SA572-S42 (included in drawing 420-0000) and are mounted to the head, thorax, and pelvis assemblies as shown in drawing 420-0000 (both incorporated by reference, see § 572.170), sheet 2 of 6.
(c) The outputs of transducers installed in the dummy and in the test equipment specified by this part are to be recorded in individual data channels that conform to SAE Recommended Practice J211 (incorporated by reference, see § 572.170) except as noted, with channel frequency classes as follows:
(1) Pendulum acceleration, CFC 180,
(2) Pendulum D-plane rotation (if transducer is used), CFC 60,
(3) Torso flexion pulling force (if transducer is used), CFC 60,
(4) Head acceleration, CFC 1000,
(5) Neck forces, upper and lower, CFC 1000,
(6) Neck moments, upper and lower, CFC 600,
(7) Thorax CG acceleration, CFC 180,
(8) Sternum deflection, Class 600,
(9) Sternum and rib accelerations, Class 1000,
(10) Spine accelerations, CFC 180,
(11) Lumbar forces, CFC 1000,
(12) Lumbar moments, CFC 600,
(13) Shoulder forces, CFC 180,
(14) Pelvis accelerations, CFC 1000,
(15) Iliac forces, CFC 180,
(16) Femur and tibia forces, CFC 600,
(17) Femur and tibia moments, CFC 600.
(18) Thorax probe acceleration, CFC 180,
(19) Knee probe acceleration, CFC 600.
(d) Coordinate signs for instrumentation polarity are to conform to SAE Information Report J1733 (incorporated by reference, see § 572.170).
(e) The mountings for sensing devices have no resonant frequency less than 3 times the frequency range of the applicable channel class.
(f) Limb joints are set at one G, barely restraining the weight of the limb when it is extended horizontally. The force needed to move a limb segment is not to exceed 2G throughout the range of limb motion.
(g) Performance tests of the same component, segment, assembly, or fully assembled dummy are separated in time by not less than 30 minutes unless otherwise noted.
(h) Surfaces of dummy components may not be painted except as specified in this subpart or in drawings subtended by this subpart.
§ 572.180   Incorporated materials.
(a) The following materials are hereby incorporated into this Subpart by reference:
(1) A parts/drawing list entitled, “Parts/Drawings List, Part 572 Subpart U, Eurosid 2 with Rib Extensions (ES2re), September 2009,” incorporated by reference in § 572.181.
(2) A drawings and inspection package entitled “Parts List and Drawings, Part 572 Subpart U, Eurosid 2 with Rib Extensions (ES-2re, Alpha Version), September 2009,” consisting of:
(i) Drawing No. 175-0000, ES-2re Dummy Assembly, incorporated by reference, see §§ 572.181, 575.182, 572.184;
(ii) Drawing No. 175-1000, Head Assembly, incorporated by reference in §§ 572.181 and 572.182;
(iii) Drawing No. 175-2000, Neck Assembly Test/Cert, incorporated by reference in §§ 572.181 and 572.183;
(iv) Drawing No. 175-3000, Shoulder Assembly, incorporated by reference in §§ 572.181 and 572.184;
(v) Drawing No. 175-3500, Arm Assembly, Left, incorporated by reference in §§ 572.181 and 572.185;
(vi) Drawing No. 175-3800, Arm Assembly, Right, incorporated by reference in §§ 572.181, and 572.185;
(vii) Drawing No. 175-4000, Thorax Assembly with Rib Extensions, incorporated by reference in §§ 572.181 and 572.185;
(viii) Drawing No. 175-5000, Abdominal Assembly, incorporated by reference in §§ 572.181 and 572.186;
(ix) Drawing No. 175-5500, Lumbar Spine Assembly, incorporated by reference in §§ 572.181 and 572.187;
(x) Drawing No. 175-6000, Pelvis Assembly, incorporated by reference in §§ 572.181 and 572.188;
(xi) Drawing No. 175-7000-1, Leg Assembly—left incorporated by reference in § 572.181;
(xii) Drawing No. 175-7000-2, Leg Assembly—right incorporated by reference in § 572.181;
(xiii) Drawing No. 175-8000, Neoprene Body Suit, incorporated by reference in §§ 572.181 and 572.185; and,
(xiv) Drawing No. 175-9000, Headform Assembly, incorporated by reference in §§ 572.181, 572.183, 572.187;
(3) A procedures manual entitled “Procedures for Assembly, Disassembly and Inspection (PADI) of the EuroSID-2re 50th Percentile Adult Male Side Impact Crash Test Dummy, February 2008,” incorporated by reference in §§ 572.180(a)(2), and 572.181(a);
(4) Society of Automotive Engineers (SAE) Recommended Practice J211, Rev. Mar 95 “Instrumentation for Impact Tests—Part 1—Electronic Instrumentation”; and,
(5) SAE J1733 of 1994-12 “Sign Convention for Vehicle Crash Testing.”
(b) The Director of the Federal Register approved the materials incorporated by reference in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies of the materials may be inspected at the Department of Transportation, Docket Operations, Room W12-140, 1200 New Jersey Avenue, SE., Washington, DC 20590, telephone (202) 366-9826, and at the National Archives and Records Administration (NARA), and in electronic format through Regulations.gov. For information on the availability and inspection of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. For information on the availability and inspection of this material at Regulations.gov , call 1-877-378-5457, or go to: http://www.regulations.gov.
(c) The incorporated materials are available as follows:
(1) The Parts/Drawings List, Part 572 Subpart U, Eurosid 2 with Rib Extensions (ES2re) referred to in paragraph (a)(1) of this section, the Parts List and Drawings, Part 572 Subpart U, Eurosid 2 with Rib Extensions (ES-2re, Alpha Version) referred to in paragraph (a)(2) of this section, and the PADI document referred to in paragraph (a)(3) of this section, are available in electronic format through Regulations.gov and in paper format from Leet-Melbrook, Division of New RT, 18810 Woodfield Road, Gaithersburg, MD 20879, telephone (301) 670-0090.
(2) The SAE materials referred to in paragraphs (a)(4) and (a)(5) of this section are available from the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096, telephone 1-877-606-7323.
§ 572.181   General description.
(a) The ES-2re Side Impact Crash Test Dummy, 50th Percentile Adult Male, is defined by:
(1) The drawings and specifications contained in the “Parts List and Drawings, Part 572 Subpart U, Eurosid 2 with Rib Extensions (ES-2re, Alpha Version), September 2009,” (incorporated by reference, see § 572.180), which includes the technical drawings and specifications described in Drawing 175-0000, the titles of which are listed in Table A;
Table A
(2) “Parts/Drawings List, Part 572 Subpart U, Eurosid 2 with Rib Extensions (ES2re), September 2009,” containing 9 pages, incorporated by reference, see § 572.180,
(3) A listing of available transducers-crash test sensors for the ES-2re Crash Test Dummy is shown in drawing 175-0000 sheet 4 of 6, dated February 2008, incorporated by reference, see § 572.180,
(4) Procedures for Assembly, Disassembly and Inspection (PADI) of the ES-2re Side Impact Crash Test Dummy, February 2008, incorporated by reference, see § 572.180,
(5) Sign convention for signal outputs reference document SAE J1733 Information Report, titled “Sign Convention for Vehicle Crash Testing” dated December 1994, incorporated by reference, see § 572.180.
(b) Exterior dimensions of ES-2re test dummy are shown in drawing 175-0000 sheet 3 of 6, dated February 2008, incorporated by reference, see § 572.180.
(c) Weights of body segments (head, neck, upper and lower torso, arms and upper and lower segments) and the center of gravity location of the head are shown in drawing 175-0000 sheet 2 of 6, dated February 2008, incorporated by reference, see § 572.180.
(d) Adjacent segments are joined in a manner such that, except for contacts existing under static conditions, there is no additional contact between metallic elements of adjacent body segments throughout the range of motion.
(e) The structural properties of the dummy are such that the dummy conforms to this Subpart in every respect before use in any test similar to those in Standard No. 214, Side Impact Protection and Standard No. 201, Occupant Protection in Interior Impact.
§ 572.182   Head assembly.
(a) The head assembly consists of the head (drawing 175-1000), including the neck upper transducer structural replacement, and a set of three (3) accelerometers in conformance with specifications in § 572.189(b) and mounted as shown in drawing (175-0000 sheet 1 of 6). When tested to the test procedure specified in paragraph (b) of this section, the head assembly shall meet performance requirements specified in paragraph (c) of this section.
(b) Test procedure. The head shall be tested per procedure specified in 49 CFR § 572.112(a).
(c) Performance criteria. (1) When the head assembly is dropped in accordance with § 572.112 (a), the measured peak resultant acceleration shall be between 125 g's and 155 g's;
(2) The resultant acceleration-time curve shall be unimodal to the extent that oscillations occurring after the main acceleration pulse shall not exceed 15% (zero to peak) of the main pulse;
(3) The fore-and-aft component of the head acceleration shall not exceed 15 g's.
§ 572.183   Neck assembly.
(a) The neck assembly consists of parts shown in drawing 175-2000. For purposes of this test, the neck is mounted within the headform assembly 175-9000 as shown in Figure U1 in appendix A to this subpart. When subjected to tests procedures specified in paragraph (b) of this section, the neck-headform assembly shall meet performance requirements specified in paragraph (c) of this section.
(b) Test procedure. (1) Soak the neck-headform assembly in a test environment as specified in § 572.189(n);
(2) Attach the neck-headform assembly to the part 572 subpart E pendulum test fixture as shown in Figure U2-A in appendix A to this subpart, so that the midsagittal plane of the neck-headform assembly is vertical and perpendicular to the plane of motion of the pendulum longitudinal centerline shown in Figure U2-A. Torque the half-spherical screws (175-2004) located at either end of the neck assembly to 88 ±5 in-lbs using the neck compression tool (175-9500) or equivalent;
(3) Release the pendulum from a height sufficient to allow it to fall freely to achieve an impact velocity of 3.4±0.1 m/s measured at the center of the pendulum accelerometer (Figure 22 as set forth in 49 CFR 572.33) at the time the pendulum makes contact with the decelerating mechanism. The velocity-time history of the pendulum falls inside the corridor determined by the upper and lower boundaries specified in Table 1 to paragraph (a) of this section.
(4) Allow the neck to flex without the neck-headform assembly making contact with any object;
(5) Time zero is defined in § 572.189(j).
Table 1 to Paragraph ( a )—ES-2re Neck Certification Pendulum Velocity Corridor
(c) Performance criteria. (1) The pendulum deceleration pulse is to be characterized in terms of decrease in velocity as determined by integrating the filtered pendulum acceleration response from time-zero.
(2) The maximum rotation in the lateral direction of the reference plane of the headform (175-9000) as shown in Figure U2-B in appendix A to this subpart, shall be 49 to 59 degrees with respect to the longitudinal axis of the pendulum occurring between 54 and 66 ms from time zero. Rotation of the headform-neck assembly and the neck angle with respect to the pendulum shall be measured with potentiometers specified in § 572.189(c), installed as shown in drawing 175-9000, and calculated per procedure specified in Figure U2-B in appendix A to this subpart;
(3) The decaying headform rotation vs. time curve shall cross the zero angle with respect to its initial position at time of impact relative to the pendulum centerline between 53 ms to 88 ms after the time the peak translation-rotation value is reached.
§ 572.184   Shoulder assembly.
(a) The shoulder (175-3000) is part of the body assembly shown in drawing 175-0000. When subjected to impact tests specified in paragraph (b) of this section, the shoulder assembly shall meet performance requirements of paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly, without suit and shoulder foam pad (175-3010), in a test environment as specified in § 572.189(n);
(2) The dummy is seated, as shown in Figure U3 in appendix A to this subpart, on a flat, horizontal, rigid surface covered by two overlaid 2 mm thick Teflon sheets and with no back support of the dummy's torso. The dummy's torso spine backplate is vertical within ±2 degrees and the midsagittal plane of the thorax is positioned perpendicular to the direction of the plane of motion of the impactor at contact with the shoulder. The arms are oriented forward at 50±2 degrees from the horizontal, pointing downward. The dummy's legs are horizontal and symmetrical about the midsaggital plane with the distance between the innermost point on the opposite ankle at 100 ±5 mm. The length of the elastic shoulder cord (175-3015) shall be adjusted so that a force between and including 27.5 and 32.5 N applied in a forward direction at 4 ±1 mm from the outer edge of the clavicle in the same plane as the clavicle movement, is required to initiate a forward motion of 1 to 5 mm;
(3) The impactor is the same as defined in § 572.189(a);
(4) The impactor is guided, if needed, so that at contact with the shoulder, its longitudinal axis is within ±0.5 degrees of a horizontal plane and perpendicular (±0.5 degrees) to the midsagittal plane of the dummy and the centerpoint on the impactor's face is within 5 mm of the center of the upper arm pivot bolt (5000040) at contact with the test dummy, as shown in Figure U3 in appendix A to this subpart;
(5) The impactor impacts the dummy's shoulder at 4.3±0.1 m/s.
(c) Performance criteria. The peak acceleration of the impactor is between 7.5 g's and 10.5 g's during the pendulum's contact with the dummy.
§ 572.185   Thorax (upper torso) assembly.
(a) The thorax assembly of the dummy must meet the requirements of both (b) and (c) of this section. Section 572.185(b) specifies requirements for an individual rib drop test, and § 572.185(c) specifies requirements for a full-body thorax impact test.
(b) Individual rib drop test. For purposes of this test, the rib modules (175-4002), which are part of the thorax assembly (175-4000), are tested as individual units. When subjected to test procedures specified in paragraph (b)(1) of this section, the rib modules shall meet performance requirements specified in paragraph (b)(2) of this section. Each rib is tested at both the 459 mm and 815 mm drop height tests described in paragraphs (b)(1)(v)(A) and (B) of this section.
(1) Test procedure. (i) Soak the rib modules (175-4002) in a test environment as specified in 572.189(n);
(ii) Mount the rib module rigidly in a drop test fixture as shown in Figure U7 in appendix A to this subpart with the impacted side of the rib facing up;
(iii) The drop test fixture contains a free fall guided mass of 7.78±0.01 kg that is of rigid construction and with a flat impact face 150±1.0 mm in diameter and an edge radius of ±0.25 mm;
(iv) Align the vertical longitudinal centerline of the drop mass so that the centerpoint of the downward-facing flat surface is aligned to impact the centerline of the rib rail guide system within ±2.5 mm.
(v) The impacting mass is dropped from the following heights:
(A) 459 ±5 mm
(B) 815 ±8 mm
(vi) A test cycle consists of one drop from each drop height specified in paragraph (b)(1)(v) of this section. Allow a period of not less than five (5) minutes between impacts in a single test cycle. Allow a period of not less than thirty (30) minutes between two separate cycles of the same rib module.
(2) Performance criteria.
(i) Each of the rib modules shall deflect as specified in paragraphs (b)(2)(i)(A) and (B) of this section, with the deflection measurements made with the internal rib module position transducer specified in § 572.189(d):
(A) Not less than 36 mm and not more than 40 mm when impacted by the mass dropped from 459 mm; and,
(B) Not less than 46 mm and not more than 51mm when impacted by the mass dropped from 815 mm.
(c) Full-body thorax impact test. The thorax is part of the upper torso assembly shown in drawing 175-4000. For this full-body thorax impact test, the dummy is tested as a complete assembly (drawing 175-0000) with the struck-side arm (175-3500, left arm; 175-3800, right arm) removed. The dummy's thorax is equipped with deflection potentiometers as specified in drawing SA572-S69. When subjected to the test procedures specified in paragraph (c)(1) of this section, the thorax shall meet the performance requirements set forth in paragraph (c)(2).
(1) Test Procedure. (i) Soak the dummy assembly (175-0000), with struck-side arm (175-3500, left arm; 175-3800, right arm), shoulder foam pad (175-3010), and neoprene body suit (175-8000) removed, in a test environment as specified in § 572.189(n);
(ii) The dummy is seated, as shown in Figure U4 in appendix A to this subpart, on a flat, horizontal, rigid surface covered by two overlaid 2 mm thick Teflon sheets and with no back support of the dummy's torso. The dummy's torso spine backplate is vertical within ±2 degrees and the midsagittal plane of thorax is positioned perpendicular to the direction of the plane of motion of the impactor at contact with the thorax. The non-struck side arm is oriented vertically, pointing downward. The dummy's legs are horizontal and symmetrical about the midsagittal plane with the distance between the innermost point on the opposite ankle at 100 ±5 mm;
(iii) The impactor is the same as defined in § 572.189(a);
(iv) The impactor is guided, if needed, so that at contact with the thorax its longitudinal axis is within ±0.5 degrees of horizontal and perpendicular ±0.5 degrees to the midsagittal plane of the dummy and the centerpoint of the impactor's face is within 5 mm of the impact point on the dummy's middle rib shown in Figure U4 in appendix A to this subpart;
(v) The impactor impacts the dummy's thorax at 5.5 m/s ±0.1 m/s.
(vi) Time zero is defined in § 572.189(k).
(2) Performance Criteria. (i) The individual rib modules shall conform to the following range of deflections:
(A) Upper rib not less than 34 mm and not greater than 41 mm;
(B) Middle rib not less than 37 mm and not greater than 45 mm;
(C) Lower rib not less than 37 mm and not greater than 44 mm.
(ii) The impactor force shall be computed as the product of the impact probe acceleration and its mass. The peak impactor force at any time after 6 ms from time zero shall be not less than 5100 N and not greater than 6200 N.
§ 572.186   Abdomen assembly.
(a) The abdomen assembly (175-5000) is part of the dummy assembly shown in drawing 175-0000 including load sensors specified in § 572.189(e). When subjected to tests procedures specified in paragraph (b) of this section, the abdomen assembly shall meet performance requirements specified in paragraph (c) of this section.
(b) Test procedure.
(1) Soak the dummy assembly (175-0000), without suit (175-8000) and shoulder foam pad (175-3010), as specified in § 572.189(n);
(2) The dummy is seated as shown in Figure U5 in appendix A to this subpart;
(3) The abdomen impactor is the same as specified in § 572.189(a) except that on its rectangular impact surface is affixed a special purpose block whose weight is 1.0 ±0.01 kg. The block is 70 mm high, 150 mm wide and 60 to 80 mm deep. The impact surface is flat, has a minimum Rockwell hardness of M85, and an edge radius of 4 to 5 mm. The block's wide surface is horizontally oriented and centered on the longitudinal axis of the probe's impact face as shown in Figure U5-A in appendix A to this subpart;
(4) The impactor is guided, if needed, so that at contact with the abdomen its longitudinal axis is within ±0.5 degrees of a horizontal plane and perpendicular ±0.5 degrees to the midsagittal plane of the dummy and the centerpoint on the impactor's face is aligned within 5 mm of the center point of the middle load measuring sensor in the abdomen as shown in Figure U5;
(5) The impactor impacts the dummy's abdomen at 4.0 m/s ±0.1 m/s;
(6) Time zero is defined in § 572.189(k).
(c) Performance criteria.
(1) The maximum sum of the forces of the three abdominal load sensors, specified in 572.189(e), shall be not less than 2200 N and not more than 2700 N and shall occur between 10 ms and 12.3 ms from time zero. The calculated sum of the three load cell forces must be concurrent in time.
(2) Maximum impactor force (impact probe acceleration multiplied by its mass) is not less than 4000 N and not more than 4800 N occurring between 10.6 ms and 13.0 ms from time zero.
§ 572.187   Lumbar spine.
(a) The lumbar spine assembly consists of parts shown in drawing 175-5500. For purposes of this test, the lumbar spine is mounted within the headform assembly 175-9000 as shown in Figure U1 in appendix A to this subpart. When subjected to tests procedures specified in paragraph (b) of this section, the lumbar spine-headform assembly shall meet performance requirements specified in paragraph (c) of this section.
(b) Test procedure. (1) Soak the lumbar spine-headform assembly in a test environment as specified in § 572.189(n);
(2) Attach the lumbar spine-headform assembly to the Part 572 pendulum test fixture per procedure in § 572.183(b)(2) and as shown in Figure U2-A in appendix A to this subpart. Torque the lumbar hex nut (p/n 9000057) on to the lumbar cable assembly (175-5506) to 50 ±5 in-lb;
(3) Release the pendulum from a height sufficient to allow it to fall freely to achieve an impact velocity of 6.05 ±0.1 m/s measured at the center of the pendulum accelerometer (Figure 22) at the time the pendulum makes contact with its decelerating mechanism. The velocity-time history of the pendulum falls inside the corridor determined by the upper and lower boundaries specified in Table 1 to paragraph (b) of this section;
(4) Allow the lumbar spine to flex without the lumbar spine or the headform making contact with any object;
(5) Time zero is defined in § 572.189(j).
Table 1 to paragraph ( b )—ES-2re Lumbar Spine Certification Pendulum Velocity Corridor
(c) Performance criteria. (1) The pendulum deceleration pulse is to be characterized in terms of decrease in velocity as determined by integrating the filtered pendulum acceleration response from time-zero.
(2) The maximum rotation in the lateral direction of the reference plane of the headform (175-9000) as shown in Figure U2-B in appendix A to this subpart, shall be 45 to 55 degrees with respect to the longitudinal axis of the pendulum occurring between 39 and 53 ms from time zero. Rotation of the headform-neck assembly shall be measured with potentiometers specified in § 572.189(c), installed as shown in drawing 175-9000, and calculated per procedure specified in Figure U2-B in appendix A to this subpart.
(3) The decaying headform rotation vs. time curve shall cross the zero angle with respect to its initial position at impact relative to the pendulum centerline between 37 ms to 57 ms after the time the peak translation-rotation value is reached.
§ 572.188   Pelvis.
(a) The pelvis (175-6000) is part of the torso assembly shown in drawing 175-0000. The pelvis is equipped with a pubic symphysis load sensor in conformance with § 572.189(f) and mounted as shown in drawing (175-0000 sheet 4). When subjected to tests procedures specified in paragraph (b) of this section, the pelvis assembly shall meet performance requirements specified in paragraph (c) of this section.
(b) Test procedure.
(1) Soak the dummy assembly (175-0000) without suit (175-8000) and shoulder foam pad (175-3010) as specified in § 572.189(n);
(2) The dummy is seated as specified in Figure U6 in appendix A to this subpart;
(3) The pelvis impactor is the same as specified in § 572.189(a);
(4) The impactor is guided, if needed, so that at contact with the pelvis its longitudinal axis is within ±0.5 degrees of a horizontal plane and perpendicular to the midsagittal plane of the dummy and the centerpoint on the impactor's face is within 5 mm of the center of the H-point in the pelvis, as shown in Figure U6 in appendix A to this subpart;
(5) The impactor impacts the dummy's pelvis at 4.3 ±0.1 m/s.
(6) Time zero is defined in § 572.189(k).
(c) Performance criteria. (1) The impactor force (probe acceleration multiplied by its mass) shall be not less than 4,700 N and not more than 5,400 N, occurring between 11.8 ms and 16.1 ms from time zero;
(2) The pubic symphysis load, measured with load cell specified in § 572.189(f) shall be not less than 1,230 N and not more than 1,590 N occurring between 12.2 ms and 17.0 ms from time zero.
§ 572.189   Instrumentation and test conditions.
(a) The test probe for lateral shoulder, thorax without arm, abdomen, and pelvis impact tests is the same as that specified in § 572.36(a) and the impact probe has a minimum mass moment of inertia in yaw of 9,000 kg-cm 2 , a free air resonant frequency not less than 1,000 Hz and the probe's end opposite to the impact face has provisions to mount an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe. All hardware attached directly to the impactor and one-third ( 1/3 ) of the mass of the suspension cables must be included in the calculations of the total impactor mass. The sum mass of the attachments and 1/3 cable mass must not exceed 5 percent of the total pendulum mass. No suspension hardware, suspension cables, or any other attachments to the test probe, including velocity vane, shall make contact with the dummy during the test.
(b) Accelerometers for the head, the thoracic spine, and the pelvis conform to specifications of SA572-S4.
(c) Rotary potentiometer for the neck and lumbar spine certification tests conforms to SA572-53.
(d) Linear position transducer for the thoracic rib conforms to SA572-S69.
(e) Load sensors for the abdomen conform to specifications of SA572-S75.
(f) Load sensor for the pubic symphysis conforms to specifications of SA572-77.
(g) Load sensor for the lumbar spine conforms to specifications of SA572-76.
(h) Instrumentation and sensors conform to the Recommended Practice SAE J-211 (Mar. 1995)—Instrumentation for Impact Test unless noted otherwise.
(i) All instrumented response signal measurements shall be treated to the following specifications:
(1) Head acceleration—Digitally filtered CFC 1000;
(2) Neck and lumbar spine rotations—Digitally filtered CFC 180;
(3)Neck and lumbar spine pendulum accelerations—Digitally filtered CFC 60;
(4) Pelvis, shoulder, thorax without arm, and abdomen impactor accelerations—Digitally filtered CFC 180;
(5) Abdominal and pubic symphysis force—Digitally filtered at CFC 600;
(6) Thorax deflection—Digitally filtered CFC 180.
(j)(1) Filter the pendulum acceleration data using a SAE J211 CFC 60 filter.
(2) Determine the time when the filtered pendulum accelerometer data first crosses the −10 g level (T 10 ).
(3) Calculate time-zero: T0 = T 10 −T m ,
(4) Set the data time-zero to the sample number nearest to the calculated T0.
(k)(1) Filter the pendulum acceleration data using a SAE J211 CFC 180 filter.
(2) Determine the time when the filtered pendulum accelerometer data first crosses the −1.0 m/s 2 (−.102 g) acceleration level (T0).
(3) Set the data time-zero to the sample number of the new T0.
(l) Mountings for the head, spine and pelvis accelerometers shall have no resonance frequency within a range of 3 times the frequency range of the applicable channel class.
(m) Limb joints of the test dummy are set at the force between 1 to 2 G's, which just supports the limb's weight when the limbs are extended horizontally forward. The force required to move a limb segment does not exceed 2 G's throughout the range of the limb motion.
(n) Performance tests are conducted, unless specified otherwise, at any temperature from 20.6 to 22.2 degrees C. (69 to 72 degrees F.) and at any relative humidity from 10 percent to 70 percent after exposure of the dummy to those conditions for a period of not less than 4 hours.
(o) Certification tests of the same component, segment, assembly, or fully assembled dummy shall be separated in time by a period of not less than thirty (30) minutes unless otherwise specified.
§ 572.190   Incorporated materials.
(a) The following materials are hereby incorporated into this Subpart by reference:
(1) A parts/drawing list entitled, “Parts/Drawings List, Part 572 Subpart V, SID-IIsD, July 1, 2008,”
(2) A drawings and inspection package entitled “Drawings and Specifications for the SID-IIsD Small Female Crash Test Dummy, Part 572 Subpart V, July 1, 2008,” consisting of:
(i) Drawing No. 180-0000, SID-IIsD Complete Assembly;
(ii) Drawing No. 180-1000, 6 Axis Head Assembly;
(iii) Drawing No. 180-2000, Neck Assembly;
(iv) Drawing No. 180-3000, Upper Torso Assembly;
(v) Drawing No. 180-3005, Washer, Clamping;
(vi) Drawing No. 9000021, Screw, SHCS 3/8 -16 × 1 NYLOK;
(vii) Drawing No. 900005, Screw, SHCS 1/4 -20 × 5/8 NYLOK;
(viii) Drawing No. 180-4000, Lower Torso Assembly Complete;
(ix) Drawing No. 180-5000-1, Complete Leg Assembly, Left;
(x) Drawing No. 180-5000-2, Complete Leg Assembly, Right;
(xi) Drawing No. 180-6000-1, Arm Assembly Left Molded;
(xii) Drawing No. 180-6000-2, Arm Assembly Right Molded; and,
(xiii) Drawing No. 180-9000, SID-IIsD Headform Assembly.
(3) A procedures manual entitled, “Procedures for Assembly, Disassembly, and Inspection (PADI) of the SID-IIsD Side Impact Crash Test Dummy, July 1, 2008,” incorporated by reference in § 572.191;
(4) SAE Recommended Practice J211, Rev. Mar 95 “Instrumentation for Impact Tests—Part 1—Electronic Instrumentation”; and,
(5) SAE J1733 of 1994-12, “Sign Convention for Vehicle Crash Testing.”
(b) The Director of the Federal Register approved the materials incorporated by reference in accordance with 5 U.S.C. 552(a) and 1 CFR part 51. Copies of the materials may be inspected at the Department of Transportation, Docket Operations, Room W12-140, 1200 New Jersey Avenue, SE., Washington, DC 20590, telephone (202) 366-9826, and at the National Archives and Records Administration (NARA), and in electronic format through Regulations.gov. For information on the availability and inspection of this material at NARA, call 202-741-6030, or go to: http://www.archives.gov/federal_register/code_of_federal_regulations/ibr_locations.html. For information on the availability and inspection of this material at Regulations.gov, call 1-877-378-5457, or go to: http://www.regulations.gov.
(c) The incorporated materials are available as follows:
(1) The Parts/Drawings List, Part 572 Subpart V, SID-IIsD, July 1, 2008, referred to in paragraph (a)(1) of this section, the package entitled Drawings and Specifications for SID-IIsD Small Female Crash Test Dummy, Part 572 Subpart V, July 1, 2008, referred to in paragraph (a)(2) of this section, and the PADI document referred to in paragraph (a)(3) of this section, are available in electronic format through www.Regulations.gov and in paper format from Leet-Melbrook, Division of New RT, 18810 Woodfield Road, Gaithersburg, MD 20879, (301) 670-0090.
(2) The SAE materials referred to in paragraphs (a)(4) and (a)(5) of this section are available from the Society of Automotive Engineers, Inc., 400 Commonwealth Drive, Warrendale, PA 15096, telephone 1-877-606-7323.
§ 572.191   General description.
(a) The SID-IIsD Side Impact Crash Test Dummy, small adult female, is defined by:
(1) The drawings and specifications contained in the “Drawings and Specifications for SID-IIsD Small Female Crash Test Dummy, Part 572 Subpart V, July 1, 2008,” which includes the technical drawings and specifications described in Drawing 180-0000, the titles of which are listed in Table A;
Table A
(2) The “Parts/Drawing List, Part 572 Subpart V, SID-IIsD,” dated July 1, 2008 and containing 7 pages,
(3) A listing of available transducers-crash test sensors for the SID-IIsD Side Impact Crash Test Dummy, 5th percentile adult female, is shown in drawing 180-0000 sheet 2 of 5, dated July 1, 2008,
(4) “Procedures for Assembly, Disassembly, and Inspection (PADI) of the SID-IIsD Side Impact Crash Test Dummy, July 1, 2008,” and,
(5) Sign convention for signal outputs reference document SAE J1733 Information Report, titled “Sign Convention for Vehicle Crash Testing,” dated July 12, 1994, incorporated by reference in § 572.200(k).
(b) Exterior dimensions of the SID-IIsD Small Adult Female Side Impact Crash Test Dummy are shown in drawing 180-0000 sheet 3 of 5, dated July 1, 2008.
(c) Weights and center of gravity locations of body segments are shown in drawing 180-0000 sheet 4 of 5, dated July 1, 2008.
(d) Adjacent segments are joined in a manner such that, except for contacts existing under static conditions, there is no additional contact between metallic elements of adjacent body segments throughout the range of motion.
(e) The structural properties of the dummy are such that the dummy conforms to this Subpart in every respect before use in any test similar to that set forth in Standard 214, Side Impact Protection (49 CFR 571.214).
§ 572.192   Head assembly.
(a) The head assembly consists of the head (180-1000) and a set of three (3) accelerometers in conformance with specifications in 49 CFR 572.200(d) and mounted as shown in drawing 180-0000 sheet 2 of 5. When tested to the procedure specified in paragraph (b) of this section, the head assembly shall meet performance requirements specified in paragraph (c) of this section.
(b) Test procedure. The head shall be tested according to the procedure specified in 49 CFR 572.112(a).
(c) Performance criteria.
(1) When the head assembly is dropped from either the right or left lateral incline orientations in accordance with procedure in § 572.112(a), the measured peak resultant acceleration shall be between 115 g and 137 g;
(2) The resultant acceleration-time curve shall be unimodal to the extent that oscillations occurring after the main acceleration pulse shall not exceed 15% (zero to peak) of the main pulse;
(3) The longitudinal acceleration vector (anterior-posterior direction) shall not exceed 15 g.
§ 572.193   Neck assembly.
(a) The neck assembly consists of parts shown in drawing 180-2000. For purposes of this test, the neck assembly is mounted within the headform assembly (180-9000) as shown in Figure V1 in appendix A to this subpart. When subjected to the test procedure specified in paragraph (b) of this section, the neck-headform assembly shall meet the performance requirements specified in paragraph (c) of this section.
(b) Test procedure.
(1) Soak the assembly in a test environment as specified in 49 CFR 572.200(j);
(2) Attach the neck-headform assembly, as shown in Figure V2-A or V2-B in appendix A to this subpart, to the 49 CFR Part 572 pendulum test fixture (Figure 22, 49 CFR 572.33) in either the left or right lateral impact orientations, respectively, so that the midsagittal plane of the neck-headform assembly is vertical and at right angle (90 ±1 degrees) to the plane of motion of the pendulum longitudinal centerline;
(3) Release the pendulum from a height sufficient to achieve a velocity of 5.57 ±0.06 m/s measured at the center of the pendulum accelerometer, as shown in 49 CFR Part 572 Figure 15, at the instant the pendulum makes contact with the decelerating mechanism;
(4) The neck flexes without the neck-headform assembly making contact with any object;
(5) Time zero is defined as the time of initial contact between the pendulum mounted striker plate and the pendulum deceleration mechanism;
(6) Allow a period of at least thirty (30) minutes between successive tests on the same neck assembly.
(c) Performance Criteria.
(1) The pendulum deceleration pulse is characterized in terms of decrease in velocity as obtained by integrating the pendulum acceleration output from time zero:
(2) The maximum translation-rotation of the midsagittal plane of the headform disk (180-9061 or 9062) in the lateral direction measured, with the rotation transducers specified in 49 CFR 572.200(e) shall be 71 to 81 degrees with respect to the longitudinal axis of the pendulum (see Figure V2-C in appendix A to this subpart) occurring between 50 and 70 ms from time zero;
(3) Peak occipital condyle moment shall not be higher than −36 Nm and not lower than −44 Nm. The moment measured by the upper neck load cell (Mx) shall be adjusted by the following formula: Mx(oc) 1 = Mx + 0.01778Fy;
1 Mx(oc) is the moment at occipital condyle (Newton-meters) and Fy is the lateral shear force (Newtons) measured by the load cell.
(4) The decaying moment shall cross the 0 Nm line after peak moment between 102 ms-126 ms after time zero.
§ 572.194   Shoulder.
(a) The shoulder structure is part of the upper torso assembly shown in drawing 180-3000. For the shoulder impact test, the dummy is tested as a complete assembly (drawing 180-0000). The dummy is equipped with T1 laterally oriented accelerometer as specified in 49 CFR 572.200(d), and deflection potentiometer as specified in 180-3881 configured for shoulder and installed as shown in drawing 180-0000 sheet 2 of 5. When subjected to the test procedure as specified in paragraph (b) of this section, the shoulder shall meet the performance requirements of paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly (180-0000) in a test environment as specified in 49 CFR 572.200(j).
(2) Seat the dummy, outfitted with the torso jacket (180-3450) and cotton underwear pants on a certification bench, specified in Figure V3 in appendix A to this subpart, the seat pan and the seatback surfaces of which are covered with a 2 mm thick PTFE (Teflon) sheet;
(3) Align the outermost portion of the pelvis flesh of the impacted side of the seated dummy tangent to a vertical plane located within 10 mm of the side edge of the bench as shown in Figure V4-A in appendix A to this subpart, while the midsagittal plane of the dummy is in vertical orientation.
(4) Push the dummy at the knees and at mid-sternum of the upper torso with just sufficient horizontally oriented force towards the seat back until the back of the upper torso is in contact with the seat back.
(5) While maintaining the dummy's position as specified in paragraphs (b)(3) and (4) of this section, the top of the shoulder rib mount (drawing 180-3352) orientation in the fore-and-aft direction is 24.6 ±2.0 degrees relative to horizontal, as shown in Figure V4-B in appendix A to this subpart.
(6) Adjust orientation of the legs such that they are symmetrical about the mid-sagittal plane, the thighs touch the seat pan, the inner part of the right and left legs at the knees are as close as possible to each other, the heels touch the designated foot support surface and the feet are vertical and as close together as possible.
(7) Orient the arm to point forward at 90 ±2 degrees relative to the inferior-superior orientation of the upper torso spine box incline.
(8) The impactor is specified in 49 CFR 572.200(a).
(9) The impactor is guided, if needed, so that at contact with the dummy's arm rotation centerline (ref. item 23 in drawing 180-3000) the impactor's longitudinal axis is within ±1 degree of a horizontal plane and perpendicular to the midsagittal plane of the dummy. The centerpoint of the impactor face at contact is within 2 mm of the shoulder yoke assembly rotation centerline (drawing 180-3327), as shown in Figure V4-A in appendix A to this subpart.
(10) The dummy's arm-shoulder is impacted at 4.3 ±0.1 m/s with the impactor meeting the alignment and contact point requirements of paragraph (b)(9) of this section.
(11) Allow a period of at least thirty (30) minutes between successive tests of the same shoulder assembly.
(c) Performance criteria.
(1) While the impactor is in contact with the dummy's arm, the shoulder shall compress not less than 28 mm and not more than 37 mm measured by the potentiometer specified in (a);
(2) Peak lateral acceleration of the upper spine (T1) shall not be less than 17 g and not more than 22 g;
(3) Peak impactor acceleration shall be not less than 13 g and not more than 18 g.
§ 572.195   Thorax with arm.
(a) The thorax is part of the upper torso assembly shown in drawing 180-3000. For the thorax with arm impact test, the dummy is tested as a complete assembly (drawing 180-0000). The dummy's thorax is equipped with T1 and T12 laterally oriented accelerometers as specified in 49 CFR 572.200(d), and deflection potentiometers for the thorax and shoulder as specified in 180-3881, installed as shown in drawing 180-0000 sheet 2 of 5. When subjected to the test procedure as specified in paragraph (b) of this section, the thorax shall meet performance requirements of paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly (180-0000) in a test environment as specified in 49 CFR 572.200(j).
(2) Seat the dummy, outfitted with the torso jacket (180-3450) and cotton underwear pants on a certification bench, specified in Figure V3, the seat pan and the seatback surfaces of which are covered with a 2-mm-thick PTFE (Teflon) sheet.
(3) Align the outermost portion of the pelvis flesh of the impacted side of the seated dummy tangent to a vertical plane located within 10 mm of the side edge of the bench as shown in Figure V5-A, while the midsagittal plane of the dummy is in vertical orientation.
(4) Push the dummy at the knees and at mid-sternum of the upper torso with just sufficient horizontally oriented force towards the seat back until the back of the upper torso is in contact with the seat back.
(5) While maintaining the dummy's position as specified in paragraphs (b)(3) and (4) of this section, the top of the shoulder rib mount (drawing 180-3352) orientation in the fore-and-aft direction is 24.6 ±2.0 degrees relative to horizontal as shown in Figure V5-B in appendix A to this subpart.
(6) Adjust orientation of the legs such that they are symmetrical about the mid-sagittal plane, the thighs touch the seat pan, the inner part of the right and left legs at the knees are as close as possible to each other, the heels touch the designated foot support surface and the feet are vertical and as close together as possible.
(7) Orient the arm downward to the lowest detent such that the longitudinal centerline of the arm is parallel to the inferior-superior orientation of the spine box.
(8) The impactor is specified in 49 CFR 572.200(a).
(9) The impactor is guided, if needed, so that at contact with the dummy's arm, its longitudinal axis is within ±1 degree of a horizontal plane and perpendicular to the midsagittal plane of the dummy. The centerpoint of the impactor face is within 2 mm of the vertical midpoint of the second thoracic rib and coincident with a line parallel to the seat back incline passing through the center of the shoulder yoke assembly arm rotation pivot (drawing 180-3327), as shown in Figure V5-A in appendix A to this subpart.
(10) The dummy's arm is impacted at 6.7 ±0.1 m/s.
(11) Time zero is defined as the time of contact between the impact probe and the arm.
(12) Allow a period of at least thirty (30) minutes between successive tests of the same thorax assembly.
(c) Performance criteria.
(1) While the impactor is in contact with the dummy's arm, the thoracic ribs and the shoulder shall conform to the following range of deflections:
(i) Shoulder not less than 31 mm and not more than 40 mm;
(ii) Upper thorax rib not less than 25 mm and not more than 32 mm;
(iii) Middle thorax rib not less than 30 mm and not more than 36 mm;
(iv) Lower thorax rib not less than 32 mm and not more than 38 mm;
(2) Peak lateral acceleration of the upper spine (T1) shall not be less than 34 g and not more than 43 g, and the lower spine (T12) not less than 29 g and not more than 37 g;
(3) Peak impactor acceleration after 5 ms after time zero shall be not less than 30 g and not more than 36 g.
§ 572.196   Thorax without arm.
(a) The thorax is part of the upper torso assembly shown in drawing 180-3000. For this thorax test, the dummy is tested as a complete assembly (drawing 180-0000) with the arm (180-6000) on the impacted side removed. The dummy's thorax is equipped with T1 and T12 laterally oriented accelerometers as specified in 49 CFR 572.200(d) and with deflection potentiometers for the thorax as specified in drawing 180-3881, installed as shown in drawing 180-0000 sheet 2 of 5. When subjected to the test procedure specified in paragraph (b) of this section, the thorax shall meet the performance requirements set forth in paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly (180-0000) in a test environment as specified in 49 CFR 572.200(j).
(2) Seat the dummy, outfitted with the torso jacket (180-3450) and cotton underwear pants on a calibration bench, specified in Figure V3 in appendix A to this subpart, the seat pan and the seatback surfaces of which are covered with a 2-mm-thick PTFE (Teflon) sheet.
(3) Align the outermost portion of the pelvis flesh of the impacted side of the seated dummy tangent to a vertical plane located within 10 mm of the side edge of the bench as shown in Figure V6-A, while the midsagittal plane of the dummy is in vertical orientation.
(4) Push the dummy at the knees and at mid-sternum of the upper torso with just sufficient horizontally oriented force towards the seat back until the back of the upper torso is in contact with the seat back.
(5) While maintaining the dummy's position as specified in paragraphs (b)(3) and (4) of this section, the top of the shoulder rib mount (drawing 180-3352) orientation in the fore-and-aft direction is 24.6 ±2.0 degrees relative to horizontal, as shown in Figure V6-B in appendix A to this subpart.
(6) Adjust orientation of the legs such that they are symmetrical about the mid-sagittal plane, the thighs touch the seat pan, the inner part of the right and left legs at the knees are as close as possible to each other, the heels touch the designated foot support surface and the feet are vertical and as close together as possible.
(7) The impactor is specified in 49 CFR 572.200(a).
(8) The impactor is guided, if needed, so that at contact with the thorax, its longitudinal axis is within 1 degree of a horizontal plane and perpendicular to the midsagittal plane of the dummy. The centerpoint of the impactor face is within 2 mm of the vertical midpoint of the second thorax rib and coincident with a line parallel to the seat back incline passing through the center of the shoulder yoke assembly arm rotation pivot (drawing 180-3327), as shown in Figure V6-A in appendix A to this subpart.
(9) The dummy's thorax is impacted at 4.3 ±0.1 m/s.
(10) Allow a period of at least thirty (30) minutes between successive tests of the same thorax assembly.
(c) Performance criteria.
(1) While the impactor is in contact with the dummy's thorax, the ribs shall conform to the following range of deflections:
(i) Upper thorax rib not less than 32 mm and not more than 40 mm;
(ii) Middle thorax rib not less than 39 mm and not more than 45 mm;
(iii) Lower thorax rib not less than 35 mm and not more than 43 mm;
(2) Peak acceleration of the upper spine (T1) shall not be less than 13 g and not more than 17 g and the lower spine (T12) not less than 7 g and not more than 11 g;
(3) Peak impactor acceleration shall not be less than 14 g and not more than 18 g.
§ 572.197   Abdomen.
(a) The abdomen assembly is part of the upper torso assembly (180-3000) and is represented by two ribs (180-3368) and two linear deflection potentiometers (180-3881). The abdomen test is conducted on the complete dummy assembly (180-0000) with the arm (180-6000) on the impacted side removed. The dummy is equipped with a lower spine laterally oriented accelerometer as specified in 49 CFR 572.200(d) and deflection potentiometers specified in drawing 180-3881, installed as shown in sheet 2 of drawing 180-0000. When subjected to the test procedure as specified in paragraph (b) of this section, the abdomen shall meet performance requirements of paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly (180-0000) in a test environment as specified in 49 CFR 572.200(j).
(2) Seat the dummy, outfitted with the torso jacket (180-3450) and cotton underwear pants on a calibration bench, specified in Figure V3, the seat pan and the seatback surfaces of which are covered with a 2 mm thick PTFE (Teflon) sheet.
(3) Align the outermost portion of the pelvis flesh of the impacted side of the seated dummy tangent to a vertical plane located within 10 mm of the side edge of the bench as shown in Figure V7-A in Appendix A to this subpart, while the midsagittal plane of the dummy is in vertical orientation.
(4) Push the dummy at the knees and at mid-sternum of the upper torso with just sufficient horizontally oriented force towards the seat back until the back of the upper torso is in contact with the seat back.
(5) While maintaining the dummy's position as specified in paragraph (b)(3) and (4) of this section, the top of the shoulder rib mount (drawing 180-3352) orientation in the fore-and-aft direction is 24.6 ±2.0 degrees relative to horizontal, as shown in Figure V7-B in appendix A to this subpart);
(6) Adjust orientation of the legs such that they are symmetrical about the mid-sagittal plane, the thighs touch the seat pan, the inner part of the right and left legs at the knees are as close as possible to each other, the heels touch the designated foot support surface and the feet are vertical and as close together as possible;
(7) The impactor is specified in 49 CFR 572.200(b);
(8) The impactor is guided, if needed, so that at contact with the abdomen, its longitudinal axis is within ±1 degree of a horizontal plane and perpendicular to the midsagittal plane of the dummy and the centerpoint of the impactor's face is within 2 mm of the vertical midpoint between the two abdominal ribs and coincident with a line parallel to the seat back incline passing through the center of the shoulder yoke assembly arm rotation pivot (drawing 180-3327), as shown in Figure V7-A in appendix A to this subpart;
(9) The dummy's abdomen is impacted at 4.3 ±0.1 m/s.
(10) Allow a period of at least thirty (30) minutes between successive tests of the same abdomen assembly.
(c) Performance criteria. (1) While the impact probe is in contact with the dummy's abdomen, the deflection of the upper abdominal rib shall be not less than 36 mm and not more than 47 mm, and the lower abdominal rib not less than 33 mm and not more than 44 mm.
(2) Peak acceleration of the lower spine (T12) laterally oriented accelerometer shall be not less than 9 g and not more than 14 g;
(3) Peak impactor acceleration shall be not less than 12 g and not more than 16 g.
§ 572.198   Pelvis acetabulum.
(a) The acetabulum is part of the lower torso assembly shown in drawing 180-4000. The acetabulum test is conducted by impacting the side of the lower torso of the assembled dummy (drawing 180-0000). The dummy is equipped with a laterally oriented pelvis accelerometer as specified in 49 CFR 572.200(d), acetabulum load cell SA572-S68, mounted as shown in sheet 2 of 5 of drawing 180-0000, and an unused and certified pelvis plug (180-4450). When subjected to the test procedure as specified in paragraph (b) of this section, the pelvis shall meet performance requirements of paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly (180-0000) in a test environment as specified in 49 CFR 572.200(j).
(2) Seat the dummy, without the torso jacket (180-3450) and without cotton underwear pants, as shown in Figure V8-A in appendix A to this subpart, on a calibration bench, specified in Figure V3 in appendix A to this subpart, with the seatpan and the seatback surfaces covered with a 2-mm-thick PTFE (Teflon) sheet;
(3) Align the outermost portion of the pelvis flesh of the impacted side of the seated dummy tangent to a vertical plane located within 10 mm of the side edge of the bench as shown in Figure V8-A in appendix A to this subpart, while the midsagittal plane of the dummy is in vertical orientation.
(4) Push the dummy at the knees and at mid-sternum of the upper torso with just sufficient horizontally oriented force towards the seat back until the back of the upper torso is in contact with the seat back.
(5) While maintaining the dummy's position as specified in paragraphs (b)(3) and (4) of this section, the top of the shoulder rib mount (drawing 180-3352) orientation in the fore-and-aft direction is 24.6 ±1.0 degrees relative to horizontal, as shown in Figure V8-B in appendix A to this subpart;
(6) Adjust orientation of the legs such that they are symmetrical about the mid-sagittal plane, the thighs touch the seat pan, the inner part of the right and left legs at the knees are as close as possible to each other, the heels touch the designated foot support surface and the feet are vertical and as close together as possible.
(7) Rotate the arm downward to the lowest detent such that the longitudinal centerline of the arm is parallel to the inferior-superior orientation of the spine box.
(8) The impactor is specified in 49 CFR 572.200(a).
(9) The impactor is guided, if needed, so that at contact with the pelvis, its longitudinal axis is within ±1 degree of a horizontal plane and perpendicular to the midsagittal plane of the dummy. The centerpoint of the impactor's face is in line within 2 mm of the longitudinal centerline of the 1/4 -20x 1/2 flat head cap screw through the center of the acetabulum load cell (SA572-S68), as shown in Figure V8-A in appendix A to this subpart;
(10) The dummy's pelvis is impacted at the acetabulum at 6.7 ±0.1 m/s.
(11) Time zero is defined as the time of contact between the impact probe and the pelvis plug.
(12) Allow a period of at least 120 minutes between successive tests of the same pelvis assembly.
(c) Performance criteria. While the impactor is in contact with the pelvis:
(1) Peak acceleration of the impactor is not less than 38 g and not more than 47 g;
(2) Peak lateral acceleration of the pelvis after 6 ms after time zero is not less than 34 g and not more than 42 g;
(3) Peak acetabulum force is not less than 3.60 kN and not more than 4.30 kN.
§ 572.199   Pelvis iliac.
(a) The iliac is part of the lower torso assembly shown in drawing 180-4000. The iliac test is conducted by impacting the side of the lower torso of the assembled dummy (drawing 180-0000). The dummy is equipped with a laterally oriented pelvis accelerometer as specified in 49 CFR 572.200(d), and iliac wing load cell SA572-S66, mounted as shown in sheet 2 of 5 of drawing 180-0000. When subjected to the test procedure as specified in paragraph (b) of this section, the pelvis shall meet performance requirements of paragraph (c) of this section.
(b) Test procedure. (1) Soak the dummy assembly (180-0000) in a test environment as specified in 49 CFR 572.200(j).
(2) Seat the dummy, without the torso jacket and without cotton underwear pants, as shown in Figure V9-A in appendix A to this subpart, on a flat, rigid, horizontal surface covered with a 2-mm-thick PTFE (Teflon) sheet.
(3) The legs are outstretched in front of the dummy such that they are symmetrical about the midsagittal plane, the thighs touch the seated surface, the inner part of the right and left legs at the knees are as close as possible to each other, and the feet are in full dorsiflexion and as close together as possible.
(4) Orient the arm downward to the lowest detent such that the longitudinal centerline of the arm is parallel to the inferior-superior orientation of the spine box.
(5) The midsagittal plane of the dummy is vertical, and superior surface of the lower half neck assembly load cell replacement (180-3815) in the lateral direction is within ±1 degree relative to the horizontal as shown in Figure V9-A.
(6) While maintaining the dummy's position as specified in paragraphs (b)(3), (4) and (5) of this section, the top of the shoulder rib mount (180-3352) orientation in the fore-and-aft direction is within ±1.0 degree relative to horizontal as shown in Figure V9-B in Appendix A to this subpart.
(7) The pelvis impactor is specified in 49 CFR 572.200(c).
(8) The dummy is positioned with respect to the impactor such that the longitudinal centerline of the impact probe is in line with the longitudinal centerline of the iliac load cell access hole, and the 88.9 mm dimension of the probe's impact surface is aligned horizontally.
(9) The impactor is guided, if needed, so that at contact with the pelvis, the longitudinal axis of the impactor is within ±1 degree of a horizontal plane and perpendicular to the midsagittal plane of the dummy.
(10) The dummy's pelvis is impacted at the iliac location at 4.3±0.1 m/s.
(11) Allow a period of at least 120 minutes between successive tests of the same pelvis assembly.
(c) Performance criteria. While the impactor is in contact with the pelvis:
(1) Peak acceleration of the impactor is not less than 36 g and not more than 45 g;
(2) Peak acceleration of the pelvis is not less than 28 g and not more than 39 g;
(3) Peak iliac force is not less than 4.10 kN and not more than 5.10 kN.
§ 572.200   Instrumentation and test conditions.
(a) The test probe for shoulder, lateral thorax, and pelvis-acetabulum impact tests is the same as that specified in 49 CFR 572.137(a) except that its impact face diameter is 120.70 ±0.25 mm and it has a minimum mass moment of inertia of 3646 kg-cm 2 .
(b) The test probe for the lateral abdomen impact test is the same as that specified in 572.137(a) except that its impact face diameter is 76.20 ±0.25 mm and it has a minimum mass moment of inertia of 3646 kg-cm 2 .
(c) The test probe for the pelvis-iliac impact tests is the same as that specified in 49 CFR 572.137(a) except that it has a rectangular flat impact surface 50.8 × 88.9 mm for a depth of at least 76 mm and a minimum mass moment of inertia of 5000 kg-cm 2 .
(d) Accelerometers for the head, the thoracic spine, and the pelvis conform to specifications of SA572-S4.
(e) Rotary potentiometers for the neck-headform assembly conform to SA572-S51.
(f) Instrumentation and sensors conform to the Recommended Practice SAE J-211 (March 1995), Instrumentation for Impact Test, unless noted otherwise.
(g) All instrumented response signal measurements shall be treated to the following specifications:
(1) Head acceleration—digitally filtered CFC 1000;
(2) Neck-headform assembly translation-rotation—digitally filtered CFC 60;
(3) Neck pendulum, T1 and T12 thoracic spine and pelvis accelerations—digitally filtered CFC 180;
(4) Neck forces (for the purpose of occipital condyle calculation) and moments—digitally filtered at CFC 600;
(5) Pelvis, shoulder, thorax and abdomen impactor accelerations—digitally filtered CFC 180;
(6) Acetabulum and iliac wings forces—digitally filtered at CFC 600;
(7) Shoulder, thorax, and abdomen deflection—digitally filtered CFC 600.
(h) Mountings for the head, thoracic spine and pelvis accelerometers shall have no resonant frequency within a range of 3 times the frequency range of the applicable channel class;
(i) Leg joints of the test dummy are set at the force between 1 to 2 g, which just support the limb's weight when the limbs are extended horizontally forward. The force required to move a limb segment does not exceed 2 g throughout the range of the limb motion.
(j) Performance tests are conducted, unless specified otherwise, at any temperature from 20.6 to 22.2 degrees C. (69 to 72 degrees F.) and at any relative humidity from 10% to 70% after exposure of the dummy to those conditions for a period of 4 hours.
(k) Coordinate signs for instrumentation polarity shall conform to the Sign Convention For Vehicle Crash Testing, Surface Vehicle Information Report, SAE J1733, 1994-12 (refer to § 572.191(a)(5)).
§ 572.210   Incorporation by reference.
Certain material is incorporated by reference (IBR) into this part with the approval of the Director of the Federal Register under 5 U.S.C. 552(a) and 1 CFR part 51. To enforce any edition other than that specified in this section, NHTSA must publish a document in the Federal Register and the material must be available to the public. All approved material is available for inspection at the Department of Transportation, Docket Operations, Room W12-140, 1200 New Jersey Avenue SE, Washington DC 20590, telephone 202-366-9826, and is available from the sources listed in paragraphs (a) and (b) of this section. It is also available for inspection at the National Archives and Records Administration (NARA). For information on the availability of this material at NARA, email fedreg.legal@nara.gov or go to www.archives.gov/federal-register/cfr/ibr-locations.html.
(a) NHTSA Technical Information Services, 1200 New Jersey Ave. SE, Washington, DC 20590, telephone 202-366-5965.
(1) A parts/drawing list entitled, “Parts/Drawings List, Part 572 Subpart W, Q3s Three-Year-Old Child Side Impact Dummy” dated (and revised) January 2021 (Parts/Drawings List); IBR approved for § 572.211.
(2) A drawings and inspection package entitled, “Drawings and Specifications for Q3s Three-Year-Old Child Side Impact Dummy, Part 572 Subpart W” dated (and revised) January 2021 (Drawings and Specifications); IBR approved for §§ 572.211, 572.212, 572.213, 572.214, 572.215, 572.216, 572.217, 572.218, and 572.219.
(3) A procedures manual entitled “Procedures for Assembly, Disassembly, and Inspection (PADI) of the Q3s Child Side Impact Crash Test Dummy” dated January 2021 (PADI); IBR approved for §§ 572.211, 572.215(b), 572.216(b), and 572.219(a).
(b) SAE International, 400 Commonwealth Drive, Warrendale, PA 15096, call 1-877-606-7323, https://www.sae.org/.
(1) SAE Recommended Practice J211/1, Rev. Mar 95, “Instrumentation for Impact Tests—Part 1—Electronic Instrumentation,” (SAE J211); IBR approved for § 572.219;
(2) SAE Information Report J1733 of 1994-12, “Sign Convention for Vehicle Crash Testing,” December 1994, (SAE J1733); IBR approved for § 572.219.
§ 572.211   General description.
(a) The Q3s Three-Year-Old Child Test Dummy is defined by the following materials:
(1) The Parts/Drawings List (incorporated by reference, see § 572.210);
(2) The Drawings and Specifications (incorporated by reference, see § 572.210);
(3) The PADI (incorporated by reference, see § 572.210).
(b) The structural properties of the dummy are such that the dummy conforms to this subpart in every respect before use in any test.
§ 572.212   Head assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The head assembly for this test consists of the complete head (drawing 020-1200) with head accelerometer assembly (drawing 020-1013A), and a half mass simulated upper neck load cell (drawing 020-1050).
(b) When the head assembly is tested according to the test procedure in paragraph (c) of this section, it shall have the following characteristics:
(1) Frontal head qualification test. When the head assembly is dropped from a height of 376.0 ± 1.0 mm in accordance with paragraph (c) of this section, the peak resultant acceleration at the location of the accelerometers at the head CG shall have a value between 255 G and 300 G. The resultant acceleration vs. time history curve shall be unimodal; oscillations occurring after the main pulse must be less than 10 percent of the peak resultant acceleration. The lateral acceleration shall not exceed 15 G (zero to peak).
(2) Lateral head qualification test. When the head assembly is dropped from a height of 200.0 ± 1.0 mm in accordance with paragraph (c) of this section, the peak resultant acceleration at the location of the accelerometers at the head CG shall have a value between 114 G and 140 G. The resultant acceleration vs. time history curve shall be unimodal; oscillations occurring after the main pulse must be less than 10 percent of the peak resultant acceleration. The X-component acceleration shall not exceed 15 G (zero to peak).
(c) The test procedure for the head assembly is as follows:
(1) Soak the head assembly in a controlled environment at any temperature between 20.6 and 22.2 °C and a relative humidity from 10 to 70 percent for at least four hours prior to a test.
(2) Prior to the test, clean the impact surface of the skin and the impact plate surface with isopropyl alcohol, trichloroethane, or an equivalent. The skin of the head and the impact plate surface must be clean and dry for testing.
(3)(i) For the frontal head test, suspend and orient the head assembly with the forehead facing the impact surface as shown in figure W1 in appendix A to this subpart. The lowest point on the forehead must be 376.0 ± 1.0 mm from the impact surface. Assure that the head is horizontal laterally. Adjust the head angle so that the upper neck load cell simulator is 28 ± 2 degrees forward from the vertical while assuring that the head remains horizontal laterally.
(ii) For the lateral head test, the head is dropped on the aspect that opposes the primary load vector of the ensuing full scale test for which the dummy is being qualified. A left drop set up that is used to qualify the dummy for an ensuing full scale left side impact is depicted in figure W2 in appendix A to this subpart. A right drop set-up would be the mirror image of that shown in figure W2. Suspend and orient the head assembly as shown in figure W2. The lowest point on the impact side of the head must be 200.0 ± 1.0 mm from the impact surface. Assure that the head is horizontal in the fore-aft direction. Adjust the head angle so that the head base plane measured from the base surface of the upper neck load cell simulator is 35 ± 2 degrees forward from the vertical while assuring that the head remains horizontal in the fore-aft direction.
(4) Drop the head assembly from the specified height by means that ensure a smooth, instant release onto a rigidly supported flat horizontal steel plate which is 50.8 mm thick and 610 mm square. The impact surface shall be clean, dry and have a surface finish of not less than 0.2 microns (RMS) and not more than 2.0 microns (RMS).
(5) Allow at least 2 hours between successive tests on the same head.
§ 572.213   Neck assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a)(1) The neck and headform assembly for the purposes of the fore-aft neck flexion and lateral neck flexion qualification tests, as shown in figures W3 and W4 in appendix A to this subpart, consists of the headform (drawing 020-9050, sheet 1) with angular rate sensor installed (drawing SA572-S58), six-channel neck/lumbar load cell (drawing SA572-S8), neck assembly (drawing 020-2400), neck/torso interface plate (drawing 020-9056) and pendulum interface plate (drawing 020-9051) with angular rate sensor installed (drawing SA572-S58).
(2) The neck assembly for the purposes of the neck torsion qualification test, as shown in figure W5 in appendix A to this subpart, consists of the neck twist fixture (drawing DL210-200) with rotary potentiometer installed (drawing SA572-S51), neck adaptor plate assembly (drawing DL210-220), neck assembly (drawing 020-2400), six-channel neck/lumbar load cell (drawing SA572-S8), and twist fixture end plate (drawing DL210-210).
(b) When the neck and headform assembly as defined in paragraph (a)(1) of this section, or the neck assembly as defined in paragraph (a)(2) of this section, is tested according to the test procedure in paragraph (c) of this section, it shall have the following characteristics:
(1) Fore-aft neck flexion qualification test. (i) Plane D, referenced in figure W3 in appendix A to this subpart, shall rotate in the direction of pre-impact flight with respect to the pendulum's longitudinal centerline between 69.5 degrees and 81.0 degrees. During the time interval while the rotation is within these angles, the peak moment measured by the neck transducer (drawing SA572-S8) shall have a value between 41.5 N-m and 50.7 N-m.
(ii) The decaying headform rotation vs. time curve shall cross the zero angle with respect to its initial position at time of impact relative to the pendulum centerline between 45 to 55 ms after the time the peak rotation value is reached.
(iii) All instrumentation data channels are defined to be zero when the longitudinal centerline of the neck and pendulum are parallel.
(iv) The headform rotation shall be calculated by the following formula with the integration beginning at time zero:
(v) (Headform Angular Rate) y is the angular rate about the y-axis in deg/sec measured on the headform (drawing 020-9050, sheet 1), and (Pendulum Angular Rate) y is the angular rate about the y-axis in deg/sec measured on the pendulum interface plate (drawing 020-9051).
(2) Lateral neck flexion qualification test. (i) Plane D, referenced in Figure W4 in appendix A to this subpart, shall rotate in the direction of pre-impact flight with respect to the pendulum's longitudinal centerline between 76.5 degrees and 87.5 degrees. During the time interval while the rotation is within these angles, the peak moment measured by the neck transducer (drawing SA572-S8) shall have a value between 25.3 N-m and 32.0 N-m.
(ii) The decaying headform rotation vs. time curve shall cross the zero angle with respect to its initial position at time of impact relative to the pendulum centerline between 61 to 71 ms after the time the peak rotation value is reached.
(iii) All instrumentation data channels are defined to be zero when the longitudinal centerline of the neck and pendulum are parallel.
(iv) The headform rotation shall be calculated by the following formula with the integration beginning at time zero:
(v) (Headform Angular Rate) y is the angular rate about the y-axis in deg/sec measured on the headform (drawing 020-9050, sheet 1), and (Pendulum Angular Rate) y is the angular rate about the y-axis in deg/sec measured on the pendulum interface plate (drawing 020-9051).
(3) Neck torsion qualification test. (i) The neck twist fixture (drawing DL210-200), referenced in figure W5 in appendix A to this subpart, shall rotate in the direction of pre-impact flight with respect to the pendulum's longitudinal centerline between 74.5 degrees and 91.0 degrees, as measured by the rotary potentiometer (drawing SA572-S51). During the time interval while the rotation is within these angles, the peak moment measured by the neck transducer (drawing SA572-S8) shall have a value between 8.0 N-m and 10.0 N-m.
(ii) The decaying neck twist fixture rotation vs. time curve shall cross the zero angle with respect to its initial position at time of impact relative to the pendulum centerline between 85 to 102 ms after the time the peak rotation value is reached.
(iii) All instrumentation data channels are defined to be zero when the zero pins are installed such that the neck is not in torsion.
(c) The test procedure for the neck assembly is as follows:
(1) Soak the neck assembly in a controlled environment at any temperature between 20.6 and 22.2 °C and a relative humidity between 10 and 70 percent for at least four hours prior to a test.
(2)(i) For the fore-aft neck flexion test, mount the neck and headform assembly, defined in paragraph (a)(1) of this section, on the pendulum, described in figure 22 to § 572.33, so that the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum, and with the neck placement such that the front side of the neck is closest to the honeycomb material as shown in figure W3 in appendix A to this subpart.
(ii) For the lateral neck flexion test, the test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A right flexion test set-up that is used to qualify the dummy for an ensuing full scale right side impact is depicted in figure W4 in appendix A to this subpart. A left flexion test set-up would be depicted by a mirror image of all components beneath the pendulum interface plate in Figure W4. Mount the neck and headform assembly, defined in paragraph (a)(1) of this section, on the pendulum, described by figure 22 to § 572.33, so that the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum, and with the neck placement such that the right (or left) side of the neck is closest to the honeycomb material as shown in figure W4.
(iii) For the neck torsion test, the test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A right torsion test set-up that is used to qualify the dummy for an ensuing full scale right side impact is depicted in figure W5 in appendix A to this subpart. A left flexion test set-up would be a mirror image of that shown in figure W5. Mount the neck assembly, defined in paragraph (a)(2) of this section, on the pendulum, described by figure 22 to § 572.33, as shown in figure W5.
(3)(i) Release the pendulum and allow it to fall freely from a height to achieve an impact velocity of 4.7 ± 0.1 m/s for fore-aft flexion, 3.8 ± 0.1 m/s for lateral flexion, and 3.6 ± 0.1 m/s for torsion, measured by an accelerometer mounted on the pendulum at time zero.
(ii) Stop the pendulum from the initial velocity with an acceleration vs. time pulse that meets the velocity change as specified in table 1 to this section. Integrate the pendulum accelerometer data channel to obtain the velocity vs. time curve beginning at time zero.
(iii) Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material.
Table 1 to § 572.213
§ 572.214   Shoulder assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The shoulder assembly for this test consists of the torso assembly (drawing 020-4500) with string pot assembly (drawing SA572-S38 or SA572-S39) installed.
(b) When the center of the shoulder of a completely assembled dummy (drawing 020-0100) is impacted laterally by a test probe conforming to § 572.219, at 3.6 ± 0.1 m/s according to the test procedure in paragraph (c) of this section:
(1) Maximum lateral shoulder displacement (compression) relative to the spine, measured with the string potentiometer assembly (drawing SA572-S38 or SA572-S39), must not be less than 17.0 mm and not more than 22.0 mm. The peak force, measured by the impact probe as defined in § 572.219 and calculated in accordance with paragraph (b)(2) of this section, shall have a value between 1123 N and 1437 N.
(2) The force shall be calculated by the product of the impactor mass and its measured deceleration.
(c) The test procedure for the shoulder assembly is as follows:
(1) The dummy is clothed in the Q3s suit (drawing 020-8001). No additional clothing or shoes are placed on the dummy.
(2) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C and a relative humidity from 10 to 70 percent for at least four hours prior to a test.
(3) The shoulder test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A left shoulder test set-up that is used to qualify the dummy for an ensuing full scale left side impact is depicted in figure W6 in appendix A to this subpart. A right shoulder set-up would be a mirror image of that shown in figure W6. Seat the dummy on the qualification bench described in figure V3 to § 572.194, the seat pan and seat back surfaces of which are covered with thin sheets of PTFE (Teflon) (nominal stock thickness: 2 to 3 mm) along the impact side of the bench.
(4) Position the dummy on the bench as shown in Figure W6, with the ribs making contact with the seat back oriented 24.6 degrees relative to vertical, the legs extended forward along the seat pan oriented 21.6 degrees relative to horizontal with the knees spaced 40 mm apart. Position the arms so that the upper arms are parallel to the seat back (±2 degrees) and the lower arms are parallel to the dummy's sagittal plane and perpendicular to the upper arms. Move the elbows inward (medially) until initial contact occurs between the sleeve and the portion of the suit covering the thorax while maintaining the relationships between the arms, seat back, and sagittal plane.
(5) The target point of the impact is a point on the shoulder that is 15 mm above and perpendicular to the midpoint of a line connecting the centers of the bolt heads of the two lower bolts (part #5000010) that connect the upper arm assembly (020-9750) to the shoulder ball retaining ring (020-3533).
(6) Impact the shoulder with the test probe so that at the moment of contact the probe's longitudinal centerline should be horizontal (±1 degree), and the centerline of the probe should be within 2 mm of the target point.
(7) Guide the test probe during impact so that there is no significant lateral, vertical, or rotational movement.
(8) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.215   Thorax with arm assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The thorax assembly for this test consists of the torso assembly (drawing 020-4500) with an IR-TRACC (drawing SA572-S37) installed.
(b) When the thorax of a completely assembled dummy (drawing 020-0100) is impacted laterally by a test probe conforming to § 572.219 at 5.0 ± 0.1 m/s according to the test procedure in paragraph (c) of this section:
(1) Maximum lateral thorax displacement (compression) relative to the spine, measured with the IR-TRACC (drawing SA572-S37) and processed as set out in the PADI (incorporated by reference, see § 572.210), shall have a value between 22.5 mm and 27.5 mm. The peak force occurring after 5 ms, measured by the impact probe as defined in § 572.219 and calculated in accordance with paragraph (b)(2) of this section, shall have a value between 1360 N and 1695 N.
(2) The force shall be calculated by the product of the impactor mass and its measured deceleration.
(3) Time zero is defined as the time of contact between the impact probe and the arm. All channels should be at a zero level at this point.
(c) The test procedure for the thorax with arm assembly is as follows:
(1) The dummy is clothed in the Q3s suit (drawing 020-8001). No additional clothing or shoes are placed on the dummy.
(2) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C and a relative humidity from 10 to 70 percent for at least four hours prior to a test.
(3) The test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A left thorax test set-up that is used to qualify the dummy for an ensuing full scale left side impact is depicted in figure W7 in appendix A to this subpart. A right thorax set-up would be a mirror image of that shown in figure W7. Seat the dummy on the qualification bench described in figure V3 to § 572.194, the seat pan and seat back surfaces of which are covered with thin sheets of PTFE (Teflon) (nominal stock thickness: 2 to 3 mm) along the impact side of the bench.
(4) Position the dummy on the bench as shown in figure W7 in appendix A to this subpart, with the ribs making contact with the seat back oriented 24.6 degrees relative to vertical, the legs extended forward along the seat pan oriented 21.6 degrees relative to horizontal with the knees spaced 40 mm apart. On the non-impact side of the dummy, the long axis of the upper arm is positioned parallel to the seat back (±2 degrees). On the impact side, the upper arm is positioned such that the target point intersects its long axis as described in paragraph (c)(5) of this section. The long axis of the upper arm is defined by section line A-A in drawing 020-9750. Both of the lower arms are set perpendicular to the upper arms and parallel to the dummy's sagittal plane. Move the elbows inward (medially) until initial contact occurs between the sleeve and the portion of the suit covering the thorax while maintaining the relationships between the arms, seat back, and sagittal plane.
(5) The target point of the impact is the point of intersection on the lateral aspect of the upper arm and a line projecting from the thorax of the dummy. The projecting line is horizontal, runs parallel to the coronal plane of the dummy, and passes through the midpoint of a line connecting the centers of the bolt heads of the two IR-TRACC bolts (part #5000646). The projected line should intersect the upper arm within 2 mm of its long axis.
(6) Impact the arm with the test probe so that at the moment of contact the probe's longitudinal centerline should be horizontal (±1 degrees), and the centerline of the probe should be within 2 mm of the target point.
(7) Guide the test probe during impact so that there is no significant lateral, vertical, or rotational movement.
(8) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.216   Thorax without arm assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The thorax assembly for this test consists of the torso assembly (drawing 020-4500) with IR-TRACC (drawing SA572-S37) installed.
(b) When the thorax of a completely assembled dummy (drawing 020-0100) with the arm (drawing 020-9700 or 020-9800) on the impacted side removed is impacted laterally by a test probe conforming to § 572.219 at 3.3 ± 0.1 m/s according to the test procedure in paragraph (c) of this section:
(1) Maximum lateral thorax displacement (compression) relative to the spine, measured with the IR-TRACC (drawing SA572-S37) and processed as set out in the PADI (incorporated by reference, see § 572.210), shall have a value between 24.5 mm and 30.5 mm. The peak force, measured by the impact probe as defined in § 572.219 and calculated in accordance with paragraph (b)(2) of this section, shall have a value between 610 N and 754 N.
(2) The force shall be calculated by the product of the impactor mass and its measured deceleration.
(c) The test procedure for the thorax without arm assembly is as follows:
(1) The dummy is clothed in the Q3s suit (drawing 020-8001). No additional clothing or shoes are placed on the dummy.
(2) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C and a relative humidity from 10 to 70 percent for at least four hours prior to a test.
(3) The test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A left thorax test set-up that is used to qualify the dummy for an ensuing full scale left side impact is depicted in figure W8 in appendix A to this subpart. A right thorax set-up would be a mirror image of that shown in Figure W8. Seat the dummy on the qualification bench described in figure V3 to § 572.194, the seat pan and seat back surfaces of which are covered with thin sheets of PTFE (Teflon) (nominal stock thickness: 2 to 3 mm) along the impact side of the bench.
(4) Position the dummy on the bench as shown in figure W8 in appendix A to this subpart, with the ribs making contact with the seat back oriented 24.6 degrees relative to vertical, the legs extended forward along the seat pan oriented 21.6 degrees relative to horizontal with the knees spaced 40 mm apart, and the arm on the non-impacted side positioned so that the upper arm is parallel (±2 degrees) to the seat back and the lower arm perpendicular to the upper arm.
(5) The target point of the impact is the midpoint of a line between the centers of the bolt heads of the two IR-TRACC bolts (part #5000646).
(6) Impact the thorax with the test probe so that at the moment of contact the probe's longitudinal centerline should be horizontal (±1 degrees), and the centerline of the probe should be within 2 mm of the target point.
(7) Guide the test probe during impact so that there is no significant lateral, vertical, or rotational movement.
(8) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.217   Lumbar spine assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The lumbar spine and headform assembly for the purposes of the fore-aft lumbar flexion and lateral lumbar flexion qualification tests, as shown in Figures W9 and W10 in appendix A to this subpart, consists of the headform (drawing 020-9050, sheet 2) with angular rate sensor installed (drawing SA572-S58), six-channel neck/lumbar load cell (drawing SA572-S8), lumbar spine assembly (drawing 020-6000), lumbar interface plate (drawing 020-9062) and pendulum interface plate (drawing 020-9051) with angular rate sensor installed (drawing SA572-S58).
(b) When the lumbar spine and headform assembly is tested according to the test procedure in paragraph (c) of this section, it shall have the following characteristics:
(1) Fore-aft lumbar flexion qualification test. (i) Plane D, referenced in figure W9 in appendix A to this subpart, shall rotate in the direction of pre-impact flight with respect to the pendulum's longitudinal centerline between 47.0 degrees and 58.5 degrees. During the time interval while the rotation is within these angles, the peak moment measured by the neck/lumbar transducer (drawing SA572-S8) shall have a value between 78.2 N-m and 96.2 N-m.
(ii) The decaying headform rotation vs. time curve shall cross the zero angle with respect to its initial position at time of impact relative to the pendulum centerline between 49 to 59 ms after the time the peak rotation value is reached.
(iii) All instrumentation data channels are defined to be zero when the longitudinal centerline of the lumbar spine and pendulum are parallel.
(iv) The headform rotation shall be calculated by the following formula with the integration beginning at time zero:
(v) (Headform Angular Rate) y is the angular rate about the y-axis in deg/sec measured on the headform (drawing 020-9050, sheet 2), and (Pendulum Angular Rate) y is the angular rate about the y-axis in deg/sec measured on the pendulum interface plate (drawing 020-9051).
(2) Lateral lumbar flexion qualification test. (i) Plane D, referenced in figure W10, shall rotate in the direction of pre-impact flight with respect to the pendulum's longitudinal centerline between 46.1 degrees and 58.2 degrees. During the time interval while the rotation is within these angles, the peak moment measured by the neck/lumbar transducer (drawing SA572-S8) shall have a value between 79.4 N-m and 98.1 N-m.
(ii) The decaying headform rotation vs. time curve shall cross the zero angle with respect to its initial position at time of impact relative to the pendulum centerline between 48 to 59 ms after the time the peak rotation value is reached.
(iii) All instrumentation data channels are defined to be zero when the longitudinal centerline of the lumbar spine and pendulum are parallel.
(iv) The headform rotation shall be calculated by the following formula with the integration beginning at time zero:
Headform rotation (deg) = ∫ [(Headform Angular Rate) y −(Pendulum Angular Rate) y ] dt
(c) The test procedure for the lumbar spine assembly is as follows:
(1) Soak the lumbar spine assembly in a controlled environment at any temperature between 20.6 and 22.2 °C and a relative humidity between 10 and 70 percent for at least four hours prior to a test.
(2)(i) For the fore-aft lumbar flexion test, mount the lumbar spine and headform assembly, defined in paragraph (a) of this section, on the pendulum described Figure 22 to § 572.33 so that the midsagittal plane of the headform is vertical and coincides with the plane of motion of the pendulum, and with the lumbar spine placement such that the front side of the lumbar spine is closest to the honeycomb material.
(ii) For the lateral lumbar flexion test, the test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A right flexion test set-up that is used to qualify the dummy for an ensuing a full scale right side impact is depicted in figure W10 in appendix A to this subpart. A left flexion test set-up would be depicted by a mirror image of all components beneath the pendulum interface plate in Figure W10. Mount the lumbar spine and headform assembly, defined in paragraph (a)(1) of this section, on the pendulum described in figure 22 to § 572.33 so that the midsagittal plane of the headform is vertical and perpendicular to the direction of motion of the pendulum, and with the lumbar spine placement such that the right (or left) side of the lumbar spine is closest to the honeycomb material.
(3)(i) Release the pendulum and allow it to fall freely from a height to achieve an impact velocity of 4.4 ± 0.1 m/s, measured by an accelerometer mounted on the pendulum as shown in Figure 22 to § 572.33 at time zero.
(ii) Stop the pendulum from the initial velocity with an acceleration vs. time pulse that meets the velocity change as specified in table 1 to this section. Integrate the pendulum accelerometer data channel to obtain the velocity vs. time curve beginning at time zero.
(iii) Time zero is defined as the time of initial contact between the pendulum striker plate and the honeycomb material.
Table 1 to § 572.217
§ 572.218   Pelvis assembly and test procedure.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The pelvis assembly (drawing 020-7500) for this test may include either a uniaxial pubic load cell (drawing SA572-S7) or a pubic load cell structural replacement (drawing 020-7150) installed on the non-impact side of the pelvis.
(b) When the center of the pelvis of a completely assembled dummy (drawing 020-0100) is impacted laterally by a test probe conforming to § 572.219 at 4.0 ± 0.1 m/s according to the test procedure in paragraph (c) of this section:
(1) The peak force, measured by the impact probe as defined in § 572.219 and calculated in accordance with paragraph (b)(2) of this section, shall have a value between 1587 N and 1901 N.
(2) The force shall be calculated by the product of the impactor mass and its measured deceleration.
(c) The test procedure for the pelvis assembly is as follows:
(1) The dummy is clothed in the Q3s suit (drawing 020-8001). No additional clothing or shoes are placed on the dummy.
(2) Soak the dummy in a controlled environment at any temperature between 20.6 and 22.2 °C (69 and 72 °F) and a relative humidity from 10 to 70 percent for at least four hours prior to a test.
(3) The pelvis test is carried out in the direction opposing the primary load vector of the ensuing full scale test for which the dummy is being qualified. A left pelvis test set-up that is used to qualify the dummy for an ensuing full scale left side impact is depicted in figure W11 in appendix A to this subpart. A right pelvis test set-up would be a mirror image of that shown in figure W11. Seat the dummy on the qualification bench described in figure V3 to § 572.194, the seat pan and seat back surfaces of which are covered with thin sheets of PTFE (Teflon) (nominal stock thickness: 2 to 3 mm) along the impact side of the bench.
(4) Position the dummy on the bench as shown in figure W11 in appendix A to this subpart, with the ribs making contact with the seat back oriented 24.6 degrees relative to vertical, the legs extended forward along the seat pan oriented 21.6 degrees relative to horizontal with the knees spaced 40 mm apart. The arms should be positioned so that the arm on the non-impacted side is parallel to the seat back with the lower arm perpendicular to the upper arm, and the arm on the impacted side is positioned upwards away from the pelvis.
(5) Establish the impact point at the center of the pelvis so that the impact point of the longitudinal centerline of the probe is located 185 mm from the center of the knee pivot screw (part #020-9008) and centered vertically on the femur.
(6) Impact the pelvis with the test probe so that at the moment of contact the probe's longitudinal centerline should be horizontal (±1 degrees), and the centerline of the probe should be within 2 mm of the center of the pelvis.
(7) Guide the test probe during impact so that there is no significant lateral, vertical, or rotational movement.
(8) No suspension hardware, suspension cables, or any other attachments to the probe, including the velocity vane, shall make contact with the dummy during the test.
§ 572.219   Test conditions and instrumentation.
All assemblies and drawings referenced in this section are contained in Drawings and Specifications, incorporated by reference, see § 572.210.
(a) The following test equipment and instrumentation is needed for qualification as set forth in this subpart:
(1) The test probe for shoulder, thorax, and pelvis impacts is of rigid metallic construction, concentric in shape, and symmetric about its longitudinal axis. It has a mass of 3.81 ± 0.02 kg and a minimum mass moment of inertia of 560 kg-cm 2 in yaw and pitch about the CG. One-third ( 1/3 ) of the weight of the suspension cables and their attachments to the impact probe is included in the calculation of mass, and such components may not exceed five percent of the total weight of the test probe. The impacting end of the probe, perpendicular to and concentric with the longitudinal axis, is at least 25.4 mm long, and has a flat, continuous, and non-deformable 70.0 ± 0.25 mm diameter face with an edge radius between 6.4-12.7 mm. The probe's end opposite to the impact face has provisions for mounting of an accelerometer with its sensitive axis collinear with the longitudinal axis of the probe. No concentric portions of the impact probe may exceed the diameter of the impact face. The impact probe shall have a free air resonant frequency of not less than 1000 Hz, which may be determined using the procedure listed in the PADI (incorporated by reference, see § 572.210).
(2) Head accelerometers have dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 and are mounted in the head as shown in drawing 020-0100, sheet 2 of 5.
(3) The upper neck force and moment transducer has the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S8 and is mounted in the head-neck assembly as shown in drawing 020-0100, sheet 2 of 5.
(4) The angular rate sensors for the fore-aft neck flexion and lateral neck flexion qualification tests have the dimensions and response characteristics specified in drawing SA572-S58 and are mounted in the headform and on the pendulum as shown in figures W3 and W4 in appendix A to this subpart.
(5) The string potentiometer shoulder deflection transducers have the dimensions and response characteristics specified in drawing SA572-S38 or SA572-S39 and are mounted to the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(6) The IR-TRACC thorax deflection transducers have the dimensions and response characteristics specified in drawing SA572-S37 and are mounted to the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(7) The lumbar spine force and moment transducer has the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S8 and is mounted in the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(8) The angular rate sensors for the fore-aft lumbar flexion and lateral lumbar flexion qualification tests have the dimensions and response characteristics specified in drawing SA572-S58 and are mounted in the headform and on the pendulum as shown in figures W9, W10 in appendix A to this subpart.
(b) The following instrumentation may be required for installation in the dummy for compliance testing. If so, it is installed during qualification procedures as described in this subpart:
(1) The optional angular rate sensors for the head have the dimensions and response characteristics specified in any of drawings SA572-S55, SA572-S56, SA572-S57 or SA572-S58 and are mounted in the head as shown in drawing 020-0100, sheet 2 of 5.
(2) The upper spine accelerometers have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 and are mounted in the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(3) The pelvis accelerometers have the dimensions, response characteristics, and sensitive mass locations specified in drawing SA572-S4 and are mounted in the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(4) The T1 accelerometer has the dimensions, response characteristics, and sensitive mass location specified in drawing SA572-S4 and is mounted in the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(5) The lower neck force and moment transducer has the dimensions, response characteristics, and sensitive axis locations specified in drawing SA572-S8 and is mounted to the neck assembly as shown in drawing 020-0100, sheet 2 of 5.
(6) The tilt sensor has the dimensions and response characteristics specified in drawing SA572-S44 and is mounted to the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(7) The pubic force transducers have the dimensions and response characteristics specified in drawing SA572-S7 and are mounted in the torso assembly as shown in drawing 020-0100, sheet 2 of 5.
(c) The outputs of transducers installed in the dummy and in the test equipment specified by this part are to be recorded in individual data channels that conform to SAE J211 (incorporated by reference, see § 572.210) except as noted, with channel frequency classes (CFCs) as follows:
(1) Pendulum acceleration, CFC 180,
(2) Pendulum angular rate, CFC 60,
(3) Neck twist fixture rotation, CFC 60,
(4) Test probe acceleration, CFC 180,
(5) Head accelerations, CFC 1000,
(6) Headform angular rate, CFC 60,
(7) Neck moments, upper and lower, CFC 600,
(8) Shoulder deflection, CFC 180,
(9) Thorax deflection, CFC 180,
(10) Upper spine accelerations, CFC 180,
(11) T1 acceleration, CFC 180,
(12) Pubic force, CFC 180,
(13) Pelvis accelerations, CFC 1000.
(d) Coordinate signs for instrumentation polarity are to conform to SAE J1733 (incorporated by reference, see § 572.210).
(e) The mountings for sensing devices have no resonant frequency less than 3 times the frequency range of the applicable channel class.
(f) Limb joints are set at one G, barely restraining the weight of the limb when it is extended horizontally. The force needed to move a limb segment is not to exceed 2G throughout the range of limb motion.
(g) Performance tests of the same component, segment, assembly, or fully assembled dummy are separated in time by not less than 30 minutes unless otherwise noted.
(h) Surfaces of dummy components may not be painted except as specified in this subpart or in drawings subtended by this subpart.